Service & Maintenance Manual

Models
1930ES
2032ES
2632ES
2646ES
3246ES
PVC 1910
31215074
May 21, 2021 - Rev B

AS/NZS MOL 70 GB
 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

GENERAL MAINTENANCE
This section contains the general safety precautions
which must be observed during maintenance of the
mobile elevating work platform. It is of utmost impor- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SEC-
tance that maintenance personnel pay strict attention TION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR
to these warnings and precautions to avoid possible DEATH AND IS A SAFETY VIOLATION.
injury to themselves or others, or damage to the equip-
ment. A maintenance program must be followed to • USE ONLY REPLACEMENT PARTS OR COMPONENTS
ensure that the machine is safe to operate. THAT ARE APPROVED BY JLG. TO BE CONSIDERED
APPROVED, REPLACEMENT PARTS OR COMPONENTS
MUST BE IDENTICAL OR EQUIVALENT TO ORIGINAL
PARTS OR COMPONENTS.
MODIFICATION OR ALTERATION OF AN MOBILE ELEVATING WORK
• NO SMOKING IS MANDATORY. NEVER REFUEL DURING
PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM
ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS
THE MANUFACTURER.
CLOSED AND SECURE AT ALL OTHER TIMES.
The specific precautions to be observed during mainte- • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN
nance are inserted at the appropriate point in the man- PERFORMING ANY MAINTENANCE.
ual. These precautions are, for the most part, those that
apply when servicing hydraulic and larger machine • DO NOT WEAR LONG HAIR UNRESTRAINED, OR
component parts. LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE
APT TO BECOME CAUGHT ON OR ENTANGLED IN
Your safety, and that of others, is the first consideration EQUIPMENT.
when engaging in the maintenance of equipment.
Always be conscious of weight. Never attempt to move • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS
heavy parts without the aid of a mechanical device. Do ON MACHINE AND IN SERVICE MANUAL.
not allow heavy objects to rest in an unstable position. • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STAND-
When raising a portion of the equipment, ensure that ING SURFACES AND HAND HOLDS.
adequate support is provided.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED
COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED SCISSOR UNTIL
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY
THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR
RESPONSIBILITY OF THE OWNER/OPERATOR. SAFETY PROP HAS BEEN ENGAGED.
HYDRAULIC SYSTEM SAFETY • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT OFF
It should be noted that the machines hydraulic systems ALL POWER CONTROLS.
operate at extremely high potentially dangerous pres- • BATTERY SHOULD ALWAYS BE DISCONNECTED
sures. Every effort should be made to relieve any system DURING REPLACEMENT OF ELECTRICAL COMPO-
pressure prior to disconnecting or removing any por- NENTS.
tion of the system.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

31215074 A-1
 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISION LOG
Original Issue A - January 8, 2020
Revised B - May 21, 2021

A-2 31215074
 TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
SECTION 1 - SPECIFICATIONS
1.1 Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Battery Charger/AC Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Lift Speed (No Load in Platform) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Model Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.4 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Tilt Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
High Drive Speed Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.5 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.7 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.8 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.9 Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

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TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Platform Drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Footnotes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
SECTION 3 - CHASSIS & SCISSOR ARMS
3.1 Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Pump/Motor - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Pump Motor Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Drive Motor Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Common Traction System Difficulties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Power Module Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Roll Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Oil Check/Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Brakes - Manual Disengage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Hub Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Main Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Tightening and Torquing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Assembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.5 Drive Motor Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
1930ES Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
2032ES/2632ES/2646ES/3246ES Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6 Electric Drive Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Servicing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Drive Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Drive Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Drive Motor Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Drive Motor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.7 Power Module - ZAPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
ZAPI Power Module Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.8 MDI (Multifunction Digital Indicator) and Brake Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Installation:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Removal: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.9 Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Battery Maintenance and Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.10 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Battery Charger Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

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3.11 Battery Charger/Inverter (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Battery Charger/Inverter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.12 Limit Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Pothole Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Rotary Angle Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.13 Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Box Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Tilt Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.14 Scissor Arms and Platform Positioning and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.15 Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3.16 Scissor Arms Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3.17 Platform Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
SECTION 4 - HYDRAULICS
4.1 Cylinders - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Solenoid Control Valves (Bang-Bang) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Crossover Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Manual Descent Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Cylinders Without Counterbalance Valves and Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 Lift Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.5 Hydraulic Oil Fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Oil Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Slide Block Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6 Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.7 Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Steer Cylinder Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Pump Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
SECTION 5 - JLG CONTROL SYSTEM
5.1 Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
To Connect the Hand Held Analyzer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Using the Analyzer:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Changing the Access Level of the Hand Held Analyzer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Adjusting Parameters using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Tilt Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Failure Troubleshooting for the Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4 Tilt Sensor Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.5 Elevation Angle Sensor Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Tilt vs. Allowed Height Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.6 Elevation Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.7 Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.9 Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5.10 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

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SECTION 6 - DIAGNOSTIC TROUBLE CODES
6.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 DTC Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 DTC Check Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
0-0 Help Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
2-2 Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
2-3 Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
2-5 Function Prevented . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
3-1 Line Contactor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
3-2 Line Contactor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
3-3 Ground Output Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
4-2 Thermal Limit (SOA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
4-4 Battery Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-6 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-7 Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
7-7 Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
8-1 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
8-2 Platform Load Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
9-9 Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Requirements:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Applying Silicone Dielectric Compound to Amp Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
AMP Faston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
AMP Micro-Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
AMP Mini Fit Jr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Mini Fit Sr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.5 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.6 Working With Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

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7.7 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Basic check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Switch Wiring - Low Side, High Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.8 Electrical Schematics and Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.9 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

31215074 v
LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

3-1. Traction Control Circuit - ZAPI Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2. Disengage Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-3. Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-4. Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-5. Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-6. Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-7. Spindle DIsassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-8. Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-9. Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-10. Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-11. Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-12. Assembly Tool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-13. Assembly Tool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-14. Assembly Tool 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-15. Drive Motor Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-16. Bearing Pressure Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-17. Wire Harness Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-18. ZAPI Power Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-19. MDI Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-20. Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-21. Battery Charger Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-22. Battery Charger (Delta-Q) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-23. Battery Charger (Green Power). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-24. Battery Charger/Inverter Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-25. Battery Charger/Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-26. Limit Switch Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3-27. Pothole Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3-28. Tilt Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3-29. Tilt Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3-30. Arms and Platform Positioning and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3-31. Scissors Arms Assembly - 1930ES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3-32. Scissors Arms Assembly - 2032ES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3-33. Scissors Arms Assembly - 2632ES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3-34. Scissors Arms Assembly - 2646ES and 3246ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3-35. Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
4-1. Lift Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2. LIft Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-5. Gar-Max Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-6. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-7. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-8. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-9. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-10. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-11. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-12. Lift Cylinder/Pump/Tank Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-13. Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-14. Lift Cylinder Assembly (1930ES) (SH-PAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-15. Lift Cylinder Assembly (1930ES) (Serta) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-16. Lift Cylinder Assembly - Motor/Pump/Tank Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
5-1. Diagnostic Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-2. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-3. Analyzer Flow Chart (Software Version P1.14) - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5-4. Analyzer Flow Chart (Software Version P1.14) - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-5. Analyzer Flow Chart (Software Version P1.14) - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-6. Analyzer Flow Chart (Software Version P1.14) - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

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FIGURE NO. TITLE PAGE NO.

7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-6. Connector Assembly (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-7. Connector Assembly (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-8. Connector Assembly (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-9. Connector Assembly (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-11. Connector Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-13. DT/DTP Contact Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-14. HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-15. HD/HDP Locking Contacts Into Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7-18. Electrical Schematic - Sheet 1 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7-19. Electrical Schematic - Sheet 2 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7-20. Electrical Schematic - Sheet 3 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7-21. Electrical Schematic - Sheet 4 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7-22. Electrical Schematic - Sheet 5 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7-23. Electrical Schematic - Sheet 6 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7-24. Electrical Schematic - Sheet 7 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7-25. Electrical Schematic - Sheet 8 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7-26. Electrical Schematic - Sheet 9 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7-27. Electrical Schematic - Sheet 10 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7-28. Electrical Components Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
7-29. Hydraulic Schematic - USA Manufactured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7-30. Hydraulic Schematic - China Manufactured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

31215074 vii
LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Battery Charger Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-2 Battery Charger Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-3 Battery Charger Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-4 Battery Charger/AC Inverter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-5 Battery AC Inverter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-6 Lift Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-7 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-9 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-10 Premium Hydraulic Fluid (VG 15) Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-11 Biodegradable Synthetic Hydraulic Fluid (VG 32) Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-12 Tilt Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3-1 ZAPI Power Module Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-2 Diagnostic Trouble Codes (Delta Q Battery Charger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3-3 Fault Codes (Green Power). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-4 Fault Codes (Eagle Battery Charger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-5 Battery Algorithms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-6 Tilt Sensor Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3-7 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3-8 Connector Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
4-1 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-2 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-3 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-4 Valve Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
5-1 Tilt Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-2 Flash Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-3 Machine Model Adjustment - Version P1.14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-4 Machine Configuration Programming Information - Version P1.14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

viii 31215074
 SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS
1.1 MACHINE SPECIFICATIONS
Description 1930ES 2032ES 2632ES 2646ES 3246ES
Maximum Stowed Travel Grade
25% 25% 25% 25% 25%
(Gradeability)
Maximum Stowed Travel Grade (Sideslope)* 3° 3° 3° 3° 3°
Maximum Operating Slope (Fully Elevated)
Front to Back* 3° 3° 3° 3° 3°
Side to Side* 1.5° 1.5° 1.5° (Dual Capacity), 2° 2°
3° (Single Capacity)
Maximum Platform Height 18.8 ft. (5.7 m) 20 ft. (6 m) 25.4 ft. (7.75 m) 26 ft. (7.9 m) 31.8 ft. (9.7 m)
Maximum Tire Load:
ANSI: 1365 lb (620 kg) 1660 (755) 1835 lb (832 kg) 2070 lb (939 kg) 2070 lb (939 kg)
CE: 1540 lb (699 kg) 1835 lb (832 kg) 1835 lb (832 kg) 2320 lb (1052 kg) 2320 lb (1052 kg)
Ground Bearing Pressure (ANSI) 109 psi 81 psi 90 psi 87 psi 87 psi
(7.7 kg/cm2) (5.7 kg/cm2 ) (6.3 kg/cm2 ) (6.1 kg/cm2 ) (6.1 kg/cm2 )
Ground Bearing Pressure (CE) 8.7 kg/cm2 6.3 kg/cm2 6.3 kg/cm2 6.9 kg/cm2 6.9 kg/cm2
(123 psi) (90 psi) (90 psi) (98 psi) (98 psi)
Maximum Drive Speed 3 mph 3 mph 2.75 mph 2.5 mph 2.5 mph
(4.8 kmph) (4.8 kmph) (4.4 kmph) (4 kmph) (4 kmph)
Maximum Wind Speed 28 mph (12.5 m/s)
(Depending on model, market, and indoor/outdoor selection, for details see platform capacities)
Maximum Horizontal Manual Side Force:
ANSI/CSA: 100 lb force (445 N) 120 lb force (533 N) N/A 150 lb force (667 N) N/A
ANSI/CSA (Indoor): N/A N/A N/A N/A N/A
ANSI/CSA (Outdoor): N/A N/A N/A N/A N/A
ANSI/CSA (Zone A): N/A N/A 120 lb force (533 N) N/A 150 lb force (667 N)
ANSI/CSA (Zone B): N/A N/A 100 lb force (445 N) N/A 105 lb force (467 N)
CE (Indoor): 90 lb force (400 N) 90 lb force (400 N) 90 lb force (400 N) 90 lb force (400 N) 90 lb force (400 N)
CE (Outdoor): 45 lb force (200 N) 45 lb force (200 N) N/A 90 lb force (400 N) 45 lb force (200 N)
AUS (Indoor): 90 lb force (400 N) 90 lb force (400 N) N/A 90 lb force (400 N) N/A
AUS (Indoor Zone A): N/A N/A 90 lb force (400 N) N/A 90 lb force (400 N)
AUS (Indoor Zone B): N/A N/A 90 lb force (400 N) N/A 90 lb force (400 N)
AUS (Outdoor): 45 lb force (200 N) 45 lb force (200 N) N/A 90 lb force (400 N) N/A
AUS (Outdoor Zone A): N/A N/A N/A N/A N/A
AUS (Outdoor Zone B): N/A N/A N/A N/A 45 lb force (200 N)
Inside Steer Angle 90° 90° 90° 90° 90°
Outside Steer Angle 69° 69° 69° 67° 67°
Electrical System Voltage (DC) 24V 24V 24V 24V 24V
Approximate Gross Machine Weight -
3435 lb 4335 lb 4700 lb (Single/Dual) 6035 lb 6450 lb
ANSI/CSA
Approximate Gross Machine Weight -
3435 kg 4335 kg 4700 lb (Single/Dual) 6035 kg 6450 kg
CE/Australia
Approximate Gross Machine Weight - Japan 3435 kg 4335 kg 4700 lb (Single/Dual) 6035 kg 6450 kg
Ground Clearance with pot hole
3.5 in (8.9 cm) 5 in. (12.7 cm)
protection system up
Ground Clearance with pot hole
1 in (2.5 cm) 0.75 in (1.9 cm)
protection system down
NOTE: *For Japanese specification machine labeled “Ministry of Labor Notification #70,” Tilt Setting is 5 degree (front to back and side to side) regardless of elevated
platform height.

31215074 1-1
 SECTION 1 - SPECIFICATIONS

Capacities
NOTE: All platform extension capacities are 250 lb (120 kg)

AUSTRALIAN
Model ANSI/CSA CE INDOOR CE OUTDOOR AUSTRALIAN INDOOR
OUTDOOR

Max Max Max Max Max Max Max Max Max Max
Capacity Persons Capacity Persons Capacity Persons Capacity Persons Capacity Persons

500 lb
1930ES 2 230 kg 2 120 kg 1 230 kg 2 120 kg 1
(227 kg)

800 lb
2032ES 2 360 kg 2 160 kg 1 360 kg 2 160 kg 1
(363 kg)

2632ES 500 lb
2 230 kg 2 N/A N/A 230 kg 2 N/A N/A
single cap (227 kg)

2632ES 800 lb
2 360 kg 2 N/A N/A 360 kg 2 N/A N/A
dual cap to 20 ft (363 kg)

2632ES 500 lb
2 230 kg 2 N/A N/A 230 kg 2 N/A N/A
dual cap to 26 ft (227 kg)

1000 lb
2646ES 2 450 kg 2 230 kg 2 450 kg 2 230 kg 2
(454 kg)

1000 lb
3246ES to 26 ft (454 kg) 2 450kg 2 320 kg 1 450 kg 2 320 kg 1
Zone A

700 lb
3246ES to 32 ft (317 kg) 2 320kg 2 320 kg 1 320 kg 2 320 kg 1
Zone B

Fluid Capacities

Description 1930ES 2032ES 2632ES 2646ES 3246ES

Hydraulic Tank 2 Gal (7.6 L) 2 Gal (7.6 L) 3 Gal (11.3 L)

Hydraulic System (Including Tank) 2.2 Gal (8.3 L) 2.8 Gal (10.6 L) 5.3 Gal (19.9 L)

1-2 31215074
 SECTION 1 - SPECIFICATIONS

Tires

Description 1930ES 2032ES 2632ES 2646ES 3246ES

Size 323mm x 100mm 406 mm x 125 mm

Max Tire Load 2500 lb (1134 kg) 4000 lb (1814 kg)

Wheel Bolt Torque 105 - 120 ft. lbs. (142-163 Nm)

Batteries Battery Charger/AC Inverter

NOTICE Table 1-1. Battery Charger Specifications
JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS Delta-Q
ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC- DESCRIPTION
1001253952
TORY APPROVED BATTERIES.
OUTPUT
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE Nominal DC Output Voltage 24V
THROUGH JLG'S AFTERMARKET PARTS DISTRIBUTION CENTERS Maximum DC Output Voltage 36V
OR JLG'S AFTERMARKET PROGRAMS. FOR ASSISTANCE WITH
PROPER BATTERY REPLACEMENT, PLEASE CONTACT YOUR Maximum DC Output Current 27.1A
LOCAL JLG SUPPORT OFFICE. Maximum Interlock Current 1A @24V
INPUT
BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COMPAT-
IBILITY WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q AC Input Voltage 85-270VAC
BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE Nominal AC Input Voltage 100 - 240VAC
CYCLE TIMES. THE USE OF NON APPROVED BATTERIES IN YOUR
JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR AC Input Frequency 50-60 HZ
BATTERY CHARGER FAULT CODES. JLG ASSUMES NO RESPONSI- Maximum AC Input Current 7.5A
BILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM OPERATION
THE USE OF NON APPROVED BATTERIES.
AC Power Indicator Solid Blue
Motors Battery Charging Indicator (Bottom Half)
Drive Motor Low State of Charge Flashing Green
High State of Charge Solid Green
Type: Shunt Wound, Sepex 24V DC
Charge Completed Solid Green
Power: 0.65 Horsepower @ 3750 rpm
Battery Charging Indicator (Top Half)
Low State of Charge Off
Hydraulic Pump/Electric Motor Assembly High State of Charge Flashing Green
(All Models)
Charge Completed Solid Green
Type: Series Wound Permanent Magnet 24V DC Fault/error/USB Indicator
Power: 3kW Charger Fault Solid Red
External Error Condition- Caution Flashing Amber
USB Port Active Flashing Green
Safe to Remove USB Solid Green
Charging Output Indicator
Output Inactive Off
Output Active Solid Yellow

31215074 1-3
 SECTION 1 - SPECIFICATIONS

Table 1-1. Battery Charger Specifications Table 1-2. Battery Charger Specifications
Delta-Q Eagle Performance
DESCRIPTION DESCRIPTION
1001253952 1001177842
Charge Profile/error Display OUTPUT
'F' Code Internal Fault - Charging Stopped Nominal DC Output Voltage 24V
'E' Code External Fault - Charging Stopped Maximum DC Output Voltage 31.92V
Maximum DC Output Current 25A
'P' Code Displaying Algorithm Number
INPUT
USB Interface Active - Do Not
'USB' Code AC Input Voltage 108-132VAC
Remove USB
Nominal AC Input Voltage 120VAC
MECHANICAL AC Input Frequency 45-65 HZ
Operating Temperature -40° to +65° Maximum AC Input Current 12A @108VAC
Shock and Water Resistant Alumi- OPERATION
Housing
num Charging Indicator Red - 30/60/90%
Mounting Orientation Any Orientation 100% Charge Indicator Green LED
DC Battery Output Connection Fault Indicator Various LED
Wire Size 12AWG Battery Type Indicator Yellow LED
Torx Screw Size T30 PROTECTION
Output Reverse Polarity Electronic Protection - Auto Reset
Torque 4.5 NM ±5%
Output Short Circuit Electronic Protection - Auto Reset
Interlock/temp Sensor Connection AC Overload Branch Circuit Protection
Wire Size 18AWG DC Overload Current Limited
Cable Clamp and Dc Block Cover MECHANICAL
Torx Screw Size T10 Operating Temperature –22° F to +122° F (–30° C to +50° C)
PROTECTION Storage Temperature –40° F to +185° F (–40° C to +85° C)
Housing Shock and Water Resistant Aluminum
Electronic Protection With Auto
Output Reverse Polarity
Reset
Output Short Circuit Current Limited
Ac Overload Current Limited
Dc Overload Current Limited

1-4 31215074
 SECTION 1 - SPECIFICATIONS

Table 1-4. Battery Charger/AC Inverter Specifications

Table 1-3. Battery Charger Specifications
Xantrex
DESCRIPTION
Green Power 1001093839
DESCRIPTION
1001218595
DC Overload Voltage Limited - Internally Controlled
OUTPUT
MECHANICAL
Nominal DC Output Voltage 24V
Maximum DC Output Voltage 34V Operating Temperature –40° F to + 185° F (–40° C to + 85° C)
Maximum DC Output Current 30A Housing Shock and Water Resistant Aluminum
INPUT
AC Input Voltage 100-240V Table 1-5. Battery AC Inverter Specifications
AC Input Frequency 45-65 HZ
Maximum AC Input Current 8.5A Power Bright
DESCRIPTION
1001136757
OPERATION
Charging Indicator Yellow LED AC INVERTER
100% Charge Indicator Green LED Output Power (Continuous) 900 W
Output Power (Surge) 1800 W
Table 1-4. Battery Charger/AC Inverter Specifications
AC Output Current 7.5 A
Xantrex AC Output Voltage 117 ± 10% VAC
DESCRIPTION
1001093839 Output Frequency 60 Hz
AC INVERTER DC Input Voltage 20 to 30 VDC
Output Power (Continuous) 1000 W Modified Sine Wave Yes
Output Power (Surge) 3000 W PROTECTION
AC Output Current 36 A Output Reverse DC Polarity 3 X 25A Replaceable Fuse
AC Output Voltage 115 to 125 VAC MECHANICAL
Output Frequency 60 Hz Operating Temperature –4° F to + 113° F (–20° C to + 45° C)
DC Input Voltage 21.2 to 29 VDC
Remote ON/OFF Yes
Lift Speed (No Load in Platform)
Modified Sine Wave -
CHARGER NOTE: No load in platform on measured lift speeds.
Nominal DC Output Voltage 28 VDC Table 1-6. Lift Speed
Maximum DC Output Voltage 33 VDC
Maximum DC Output Current 23 to 27 ADC Model Lift Up (Seconds) Lift Down (Seconds)
Required Interlock Current 1A 1930ES 18 - 26 22 - 35
Input Voltage (AC) 100 to 130 VAC
2032ES 25 - 36 30 - 46
Nominal Input Voltage (AC) 120 VAC
Input Frequency 54 to 66 Hz 2632ES 28 - 38 32 - 40
OPERATION 2646ES 38 - 50 40 - 55
Charging Indicator Yellow LED
3246ES 50 - 62 58 - 68
100% Charge Indicator Green LED
Fault Indicator Red LED
PROTECTION
Output Reverse DC Polarity 125 A Replaceable Fuse
Output AC Short Circuit Internally Controlled
AC Overload 20 A Internal Slow Blow Charger Fuse

31215074 1-5
 SECTION 1 - SPECIFICATIONS

Travel Speed
Model Elevated Speed Maximum Speed
Unit of Measure Mph Sec/25 ft Kmph Sec/7.6 m Mph Sec/25 ft Kmph Sec/7.6 m
1930ES 0.5 28-37 0.8 33 - 38 3 5.6 - 7.7 4.8 5.6 - 7.7
2032ES 0.5 28-37 0.8 33 - 38 3 6 - 7.9 4.8 6 - 7.9
2632ES 0.5 28-37 0.8 33 - 38 2.75 6 - 7.9 4.4 6 - 7.9
2646ES 0.5 28-37 0.8 33 - 38 2.5 6.4 - 8.3 4 6.4 - 8.3
3246ES 0.5 28-37 0.8 33 - 38 2.5 6.4 - 8.3 4 6.4 - 8.3

Model Dimensions

Model 1930ES 2032ES 2632ES 2646ES 3246ES

Platform Height - Elevated 18.75 ft 20 ft 25.6 ft 26 ft 31.8 ft
(5.7 m) (6 m) (7.8 m) (7.9 m) (9.7 m)
Platform Height - Stowed 2.9 ft 3.6 ft 4 ft 4.2 ft 4.2 ft
(0.9 m) (1.1 m) (1.2 m) (1.3 m) (1.3 m)
Working Height 25 ft 26 ft 32 ft 32 ft 38 ft
(7.6 m) (7.9 m) (9.8 m) (9.8 m) (11.6 m)
Overall Stowed Machine Height - Rails Up 6.5 ft 7.2 ft 7.5 ft 7.9 ft 7.9 ft
(2 m) (2.2 m) (2.3 m) (2.4 m) (2.4 m)
Overall Stowed Machine Height - Rails Folded 5.6 ft 6 ft 6.2 ft 6.6 ft 6.6 ft
(1.6 m) (1.8 m) (1.9 m) (2 m) (2 m)
Rail Height (From platform floor) 3.6 ft 3.6 ft 3.6 ft 3.6 ft 3.6 ft
(1.1 m) (1.1 m) (1.1 m) (1.1 m) (1.1 m)
Overall Machine Width 2.5 ft 2.66 ft 2.66 ft 3.7 ft 3.7 ft
(0.8 m) (0.81 m) (0.81 m) (1.2 m) (1.2 m)
Overall Machine Length - Platform Retracted 6 ft 7.5 ft 7.5 ft 8.2 ft 8.2 ft
(1.9 m) (2.3 m) (2.3 m) (2.5 m) (2.5 m)
Overall Machine Length - Platform Extended 9 ft 10.5 ft 10.5 ft 12.4 ft 12.4 ft
(2.8 m) (3.2 m) (3.2 m) (3.8 m) (3.8 m)
Platform Size - Length 6.1 ft 7.5 ft 7.5 ft 8.2 ft 8.2 ft
(1.9 m) (2.3 m) (2.3 m) (2.5 m) (2.5 m)
Platform Size - Width 2.5 ft 2.5 ft 2.5 ft 3.7 ft 3.7 ft
(0.8 m) (0.8 m) (0.8 m) (1.1 m) (1.1 m)
Platform Extension Length 3 ft 3 ft ( 3 ft 4.2 ft 4.2 ft
(0.9 m) 0.9 m) (0.9 m) (1.3 m) (1.3 m)
Wheelbase 63 in 74 in 74 in 82.30 in 82.30 in
(160 c m) (188 c m) (188 c m) (209 cm) (209 cm)

1-6 31215074
 SECTION 1 - SPECIFICATIONS

1.2 TORQUE REQUIREMENTS 1.3 LUBRICATION

Self locking fasteners, such as nylon insert and thread Hydraulic Oil
deforming locknuts, are not intended to be reinstalled
after removal. Always use new replacement hardware NOTE: Hydraulic oils must have anti-wear qualities at least
when installing locking fasteners. to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser-
Table 1-7. Torque Requirements vice. JLG Industries recommends DTE 11M hydraulic
oil.
Description Torque Value (Dry) Interval Hours
Rear Wheel Spindle Nut 30-40 ft. lbs. NOTE: Aside from JLG recommendations, it is not advisable
50
(40-54 Nm) to mix oils of different brands or types, as they may
Wheel Bolts 105 -120 ft. lbs. not contain the same required additives or be of
50 comparable viscosities.
(142-163 Nm)
Table 1-8. Hydraulic Oil
NOTE: Anytime a wheel bolt is replaced, be sure one of the
same length is used. Use bolt shown below on wheels Hydraulic System Operating
that use the 1/4" (6.4mm) ring. SAE Viscosity Grade
Temperature Range
0°F to +23°F (-18°C to -5°C) 10W
0°F to 210°F (-18°C to + 99°C) 10W-20, 10W-30
50°F to 210°F (+10°C to +99°C) 20W-20

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
NOTE: After tightening the spindle nut to the proper torque, extreme pressure type. (Timken OK 40 pounds minimum.)
loosen completely until you can turn by hand. Finger EPGL Extreme Pressure Gear Lube (oil) meeting API service classification
tighten nut by hand without rotating hub. Install cot- GL-5 or MIL-Spec MIL-L-2105.
ter pin by backing nut off, if necessary, in order to line
up slot. HO Hydraulic Oil. API service classification GL-3,e.g. DTE 11M.

When maintenance becomes necessary or a fastener

has loosened, refer to Section 1.8, Thread Locking
Compound to determine proper torque value.

31215074 1-7
 SECTION 1 - SPECIFICATIONS

Table 1-10. Premium Hydraulic Fluid (VG 15) Specs Pressure Settings
Recommended Optional
Inspection Data
SHELL TELLUS S2 VX 15 MOBIL DTE 10 EXCEL 15 Lift Relief
ISO Viscosity Grade 15 15 Model Steer Relief
USA Built China Built
Specific Gravity 0.872 0.837
Pour Point -43.6°F (-42°C) -65.2°F (-54°C) 1800 psi ± 50 psi 1900 psi ± 50 psi 1500 psi
1930ES
(124 bar ± 3.4 bar) (131 bar ± 3.4 bar) (103 bar)
Flash Point 392°F (200°C) 359.6°F (182°C)
Base Oil Type HV HV 1800 psi ± 50 psi 1900 psi ± 50 psi 1500 psi
2032ES
(124 bar ± 3.4 bar) (131 bar ± 3.4 bar) (103 bar)
Viscosity
Brookfield, at -40°C - 2620 1950 psi +/- 50 psi 1900 psi ± 50 psi 1500 psi
2632ES
Brookfield, at -30°C - - (134 bar ± 3.4 bar) (131 bar ± 3.4 bar) (103 bar)
Brookfield, at -20°C - - 2000 psi +/- 50 psi 1900 psi ± 50 psi 1500 psi
2646ES
Brookfield, at -5°C - - (138 bar ± 3.4 bar) (131 bar ± 3.4 bar) (103 bar)
Viscosity at 40° C 15.14 cSt 15.60 cSt
2000 psi +/- 50 psi 1900 psi ± 50 psi 1500 psi
Viscosity at 100° C 3.70 cSt 4.04 cSt 3246ES
(138 bar ± 3.4 bar) (131 bar ± 3.4 bar) (103 bar)
Viscosity Index 135 169
NOTE: Check your nameplate at the left rear of the machine
Table 1-11. Biodegradable Synthetic Hydraulic Fluid for country of origin. USA built machines, serial num-
(VG 32) Specs ber prefix starts with a 02 (02XXXXXXXX), China built
machines, serial number prefix starts with an B2
Optional (B2XXXXXXXX).
Recommended
MOBIL EAL
Inspection Data SHELL NATURELLE
ENVIRONSYN
HF-E32
H32
ISO Viscosity Grade 32 32
Spec Gravity API 0.918 0.869
Flash Point, ° F(° C) 475°F (246°C) 514 °F (268°C)
Pour Point, ° F (° C) -38 °F (-39°C) -38°F (-39°C)
POLYOL ESTER FATTY ACID ESTER
Base Oil Type HEES -
HFDU -
Auto-Ignition Temp,° F (° C) >608°F(>320°C) -
Biodegradability
79% >60%
(% 28 Days)
Viscosity
Brookfield, cP at -22°F (- -
-
30°C)
Brookfield, cP at -4°F (-20°C) - -
Brookfield, cP at 23°F (-5°C) - -
Viscosity, cST at 104°F (40° C) 30.78 33.59
Viscosity, cST at 212°F (100° 6.85
6.41
C)
Viscosity Index 192 146

1-8 31215074
 SECTION 1 - SPECIFICATIONS

1.4 LIMIT SWITCHES High Drive Speed Cutout

High drive speed is cut out when the platform is raised
Tilt Alarm above the preset height per model as follows:
Illuminates a light on the platform, sounds an alarm and NOTE: These figures are given with a tolerance of ± 6 in
cuts out lift up and drive when the machine is out of
level and above stowed depending on model and speci- (0.15 m).
fications.
Model High Drive Speed Cutout
Table 1-12. Tilt Setting 1930ES 54 in (1.4 m)
Tilt Setting Tilt Setting Maximum Platform 2032ES 66 in (1.7 m)
Model
(front to back) (side to side) Elevation 2632ES 76 in (1.9 m)
1.5° 18.75 ft (5.7 m) 2646ES 76 in (1.9 m)
2° 14 ft (4.3 m) 3246ES 76 in (1.9 m)
1930ES 3°
2.5° 11 ft (3.4 m)
3° 9 ft (2.7 m)
1.5° 20 ft (6 m)
2° 15 ft (4.5 m)
2032ES 3°
2.5° 12 ft (3.7 m)
3° 10 ft (3 m)
1.5° 25.4 ft (7.7 m)
2° 20 ft (6 m)
2632ES 3°
2.5° 16 ft (4.9 m)
3° 13 ft (4 m)
2° 26 ft (7.9 m)
2646ES 3° 2.5° 22 ft (6.7 m)
3° 20 ft (6 m)
2° 31.75 ft (9.7 m)
3246ES 3° 2.5° 22 ft (6.7 m)
3° 20 ft (6 m)

31215074 1-9
 SECTION 1 - SPECIFICATIONS

1.5 CYLINDER SPECIFICATIONS

Description 1930ES 2032ES 2632ES 2646ES 3246ES

Lift Cylinder Bore 2.8 in 3.1 in 3.1 in 3.9 in 3.9 in
(7.1 cm) (7.9 cm) (7.9 cm) (9.9 cm) (9.9 cm)
Lift Cylinder Stroke 43.2 in 48 in 48 in 44.9 in 56.8 in
(108 cm) (122 cm) (122 cm) (114 cm) (144 cm)
Lift Cylinder Rod Diameter 1.8 in 2.1 in 2.1 in 2.4 in 2.4 in
(4.5 cm) (5.5 cm) (5.5 cm) (6 cm) (6 cm)
Steer Cylinder (Stroke) 6.3 in 6.3 in 6.3 in 6.1 in 6.1 in
(16 cm) (16 cm) (16 cm) (15.6 cm) (15.6 cm)

1.6 MAJOR COMPONENT WEIGHTS

Component 1930ES 2032ES 2632ES 2646ES 3246ES

Platform 100 lb 133 lb 176 lb
(45 kg) (61 kg) (80 kg)
Manual Platform Extension 45 lb (20 kg)
Arm Assembly - (Includes Lift Cylinder) 620 lb 939 lb 1,213 lb 1,645 lb
(281 kg) (426 kg) (550 kg) (746 kg)
Chassis w/Wheel/Tire and Drive Assembly 1,067 lb 1,764 lb 1,554 lb
(484 kg) (800 kg) (705 kg)

1.7 CRITICAL STABILITY WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BAT-

TERIES OR SOLID TIRES, WITH ITEMS OF DIFFERENTWEIGHT OR
SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT
STABILITY.

Component 1930 ES 2032ES 2632ES 2646ES 3246ES

Counterweight(s) (CE, AUS)
586 lb (266 kg) 726 lb (329.5 kg) 1606.7 lb (728.8 kg) 1973.8 lb (895.3 kg)
Counterweight (ANSI, CSA, JPN)
Wheel and Tire Assembly (each) 22 lb (9.8 kg) 39.7 lb (18 kg)
Wheel/Tire and Drive Assembly (each) 117 lb (53 kg) 162 lb (73.4 kg)
Lift Cylinder 176 lb(80 kg) 205 lb (93 kg) 263 lb (119 kg) 283 lb (128 kg)
Batteries: (each)
220 Amp 67 lb (30.4 kg) 67 lb (30.4 kg)
220 Amp (used with Inverter/Charger) 66 lb (30 kg) 66 lb (30 kg)
245 Amp N/A 70 lb (32 kg)

1-10 31215074
 SECTION 1 - SPECIFICATIONS

1.8 THREAD LOCKING COMPOUND

JLG PN Loctite® ND Industries Description
0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue)
1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue)
0100019 271™ Vibra-TITE™ 140 High Strength (Red)
0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red)
NOTE: Loctite® 243™ can be substituted in place of Loctite® 242™. Vibra-TITE™ 122 can be substituted in place of Vibra-TITE™ 121.

31215074 1-11
 SECTION 1 - SPECIFICATIONS

1.9 TORQUE CHARTS

SAE Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
(Loctite® 242™ or 271™ Torque
Tensile Clamp Torque Torque
Size TPI Bolt Dia or (Loctite® 262™ or
Stress Area Load (Dry) Lubricated
Vibra-TITE™ Vibra-TITE™ 131)
111 or 140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

1-12 31215074
 SECTION 1 - SPECIFICATIONS

SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque (Loctite® 242™ or 271™ or Vibra-
Tensile Stress (Loctite® 262™ or
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Area TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.20
K=0.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

31215074 1-13
 SECTION 1 - SPECIFICATIONS

SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Torque (Loctite® 242™ or 271™ or
Tensile Stress (Loctite® 262™ or
Size TPI Bolt Dia Clamp Load (Dry)
Area Vibra-TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.17
K=0.16 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

1-14 31215074
 SECTION 1 - SPECIFICATIONS

SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque (Loctite® 242™ or 271™ or
Tensile Stress (Loctite® 262™ or
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Area Vibra-TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.17
K=0.16 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 37 4
10 24 0.1900 0.01750 1580 51 6
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

31215074 1-15
 SECTION 1 - SPECIFICATIONS

SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)
SOCKET HEAD CAPSCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITE™ 111 or 140) or Vibra-TITE™ 131)
Precoat® 85 K=0.16 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

1-16 31215074
 SECTION 1 - SPECIFICATIONS

SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*
SOCKET HEAD CAPSCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITE™ 111 or 140) or Vibra-TITE™ 131)
Precoat® 85 K=0.16 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

31215074 1-17
 SECTION 1 - SPECIFICATIONS

Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*
CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
Torque
Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ (Loctite® 242™ or
Size Pitch Torque (Lube) or 271™ or
Area See Note 4 (Dry or Loctite® 263™)
Vibra-TITE™ 111 or
Vibra-TITE™ 131)
141)
Sq mm KN [N.m] [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 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

1-18 31215074
 SECTION 1 - SPECIFICATIONS

Metric Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*
CLASS 10.9 METRIC (HEX HEAD) BOLTS,
CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5*
Torque
Torque
Torque (Lube or Loctite® 242™ or
Tensile Clamp Load 271™ or (Loctite® 262™ or
Size Pitch (Dry or Loctite® 263™)
Stress Area See Note 4 Vibra-TITE™ 131)
K=0.20 Vibra-TITE™ 111 or 140)
K=0.15
K=0.18
Sq mm KN [N.m] [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 23 19
8 1.25 36.60 22.8 37 33 27
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

31215074 1-19
 SECTION 1 - SPECIFICATIONS

Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*
CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque Torque
Torque (Lube or Loctite® 242™ or (Loctite® 262™ or
Tensile Clamp Load
Size Pitch (Dry or Loctite® 263™) 271™ or Vibra-TITE™ 131)
Stress Area See Note 4
K=0.17 Vibra-TITE™ 111 or 140) K=0.15
K=0.16
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.1 1.1 1.0
3.5 0.6 6.78 2.95 1.8 1.7 1.5
4 0.7 8.78 3.82 2.6 2.4 2.3
5 0.8 14.20 6.18 5.3 4.9 4.6
6 1 20.10 8.74 9 8.4 7.9
7 1 28.90 12.6 15 14 13
8 1.25 36.60 15.9 22 20 19
10 1.5 58.00 25.2 43 40 38
12 1.75 84.30 36.7 75 70 66
14 2 115 50.0 119 110 105
16 2 157 68.3 186 175 165
18 2.5 192 83.5 256 240 225
20 2.5 245 106.5 362 340 320
22 2.5 303 132.0 494 465 435
24 3 353 153.5 627 590 555
27 3 459 199.5 916 860 810
30 3.5 561 244.0 1245 1170 1100
33 3.5 694 302.0 1694 1595 1495
36 4 817 355.5 2176 2050 1920
42 4.5 1120 487.0 3477 3275 3070

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

1-20 31215074
 SECTION 1 - SPECIFICATIONS

Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*
CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,
CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE*
Torque
Torque
Clamp Torque (Lube or Loctite® 242™ or
Tensile 271™ or (Loctite® 262™ or
Size Pitch Load See Note (Dry or Loctite® 263™)
Stress Area Vibra-TITE™ 131)
4 K=0.17 Vibra-TITE™ 111 or 140)
K=0.15
K=0.18
Sq mm KN [N.m] [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 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 55
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 222.0 905 850 800
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

31215074 1-21
 SECTION 1 - SPECIFICATIONS

1-22 31215074
 SECTION 2 - GENERAL

SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, ever comes first); out of service for a period of more than
3 months; or when purchased used. The frequency of
AND MAINTENANCE this inspection must be increased as environment,
severity and frequency of usage requires.
General
Reference the JLG Pre-Delivery and Frequent Inspection
This section provides the necessary information needed Form and the Inspection and Preventative Maintenance
by those personnel that are responsible to place the Schedule for items requiring inspection during the per-
machine in operation readiness and maintain its safe formance of these inspections. Reference the appropri-
operating condition. For maximum service life and safe ate areas of this manual for servicing and maintenance
operation, ensure that all the necessary inspections and procedures.
maintenance have been completed before placing the
machine into service. With proper care, maintenance Annual Machine Inspection
and inspections performed per JLG's recommendations
with any and all discrepancies corrected, this product JLG recommends that the Annual Machine Inspection
will be fit for continued use. be performed by a Factory Trained Service Technician
on an annual basis, no later than thirteen (13) months
Preparation, Inspection, and Maintenance from the date of the prior Annual Machine Inspection.
JLG Industries, Inc. recognizes a Factory Trained Service
It is important to establish and conform to a compre- Technician as a person who has successfully completed
hensive inspection and preventive maintenance pro- the JLG Service Training School for the subject JLG prod-
gram. The following table outlines the periodic machine uct model. Reference the machine Service and Mainte-
inspections and maintenance recommended by JLG nance Manual and appropriate JLG inspection form for
Industries, Inc. Consult your national, regional, or local performance of this inspection.
regulations for further requirements for mobile elevat-
Reference the JLG Annual Machine Inspection Form and
ing work platforms. The frequency of inspections and
the Inspection and Preventative Maintenance Schedule
maintenance must be increased as environment, sever-
for items requiring inspection during the performance
ity and frequency of usage requires.
of this inspection. Reference the appropriate areas of
Pre-Start Inspection this manual for servicing and maintenance procedures.
For the purpose of receiving safety-related bulletins, it is
It is the User’s or Operator’s primary responsibility to important that JLG Industries, Inc. has updated owner-
perform a Pre-Start Inspection of the machine prior to ship information for each machine. When performing
use daily or at each change of operator. Reference the each Annual Machine Inspection, notify JLG Industries,
Operator’s and Safety Manual for completion proce- Inc. of the current machine ownership.
dures for the Pre-Start Inspection. The Operator and
Safety Manual must be read in its entirety and under- Preventative Maintenance
stood prior to performing the Pre-Start Inspection.
In conjunction with the specified inspections, mainte-
Pre-Delivery Inspection and Frequent nance shall be performed by a qualified JLG equipment
Inspection mechanic. JLG Industries, Inc. recognizes a qualified JLG
equipment mechanic as a person who, by possession of
The Pre-Delivery Inspection and Frequent Inspection a recognized degree, certificate, extensive knowledge,
shall be performed by a qualified JLG equipment training, or experience, has successfully demonstrated
mechanic. JLG Industries, Inc. recognizes a qualified JLG the ability and proficiency to service, repair, and main-
equipment mechanic as a person who, by possession of tain the subject JLG product model.
a recognized degree, certificate, extensive knowledge,
Reference the Preventative Maintenance Schedule and
training, or experience, has successfully demonstrated
the appropriate areas of this manual for servicing and
the ability and proficiency to service, repair, and main-
maintenance procedures. The frequency of service and
tain the subject JLG product model.
maintenance must be increased as environment, sever-
The Pre-Delivery Inspection and Frequent Inspection ity and frequency of usage requires.
procedures are performed in the same manner, but at
different times. The Pre-Delivery Inspection shall be per-
formed prior to each sale, lease, or rental delivery. The
Frequent Inspection shall be accomplished for each
machine in service for 3 months or 150 hours (which-

31215074 2-1
 SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Primary Service
Type Frequency Reference
Responsibility Qualification

Pre-Start Prior to use each day; or

User or Operator User or Operator Operator and Safety Manual
Inspection At each Operator change.

Service and Maintenance Man-

Pre-Delivery Prior to each sale, lease, or
Owner, Dealer, or User Qualified JLG Mechanic ual and applicable JLG inspec-
Inspection rental delivery.
tion form.

In service for 3 months or 150 hours, whichever

comes first; or Service and Maintenance Man-
Frequent
Out of service for a period of more than 3 Owner, Dealer, or User Qualified JLG Mechanic ual and applicable JLG inspec-
Inspection
months; or tion form.
Purchased used.

Factory Trained Service and Maintenance Man-

Annual Machine Annually, no later than 13 months from the
Owner, Dealer, or User Service Technician ual and applicable JLG inspec-
Inspection date of the prior inspection.
(recommended) tion form.

Preventative At intervals as specified in the Service and Service and Maintenance Man-
Owner, Dealer, or User Qualified JLG Mechanic
Maintenance Maintenance Manual. ual

2.2 SERVICE AND GUIDELINES component is disconnected, cap or cover all open-
ings to prevent entry of foreign matter.
General 3. Clean and inspect all parts during servicing or
maintenance, and assure that all passages and
The following information is provided to assist you in
openings are unobstructed. Cover all parts to keep
the use and application of servicing and maintenance
them clean. Be sure all parts are clean before they
procedures contained in this book.
are installed. New parts should remain in their con-
tainers until they are ready to be used.
Safety and Workmanship
Your safety, and that of others, is the first consideration
Components Removal and Installation
when engaging in the maintenance of equipment. 1. Use adjustable lifting devices, whenever possible,
Always be conscious of weight. Never attempt to move if mechanical assistance is required. All slings
heavy parts without the aid of a mechanical device. Do (chains, cables, etc.) should be parallel to each
not allow heavy objects to rest in an unstable position. other and as near perpendicular as possible to top
When raising a portion of the equipment, ensure that of part being lifted.
adequate support is provided.
2. Should it be necessary to remove a component on
an angle, keep in mind that the capacity of an eye-
Cleanliness bolt or similar bracket lessens, as the angle
1. The most important single item in preserving the between the supporting structure and the compo-
long service life of a machine is to keep dirt and nent becomes less than 90°.
foreign materials out of the vital components. Pre- 3. If a part resists removal, check to see whether all
cautions have been taken to safeguard against nuts, bolts, cables, brackets, wiring, etc., have been
this. Shields, covers, seals, and filters are provided removed and that no adjacent parts are interfer-
to keep air, fuel, and oil supplies clean; however, ing.
these items must be maintained on a scheduled
basis in order to function properly.
2. At any time when air, fuel, or oil lines are discon-
nected, clear adjacent areas as well as the open-
ings and fittings themselves. As soon as a line or

2-2 31215074
 SECTION 2 - GENERAL

Component Disassembly and Reassembly Bolt Usage and Torque Application

When disassembling or reassembling a component, 1. Self locking fasteners, such as nylon insert and
complete the procedural steps in sequence. Do not par- thread deforming locknuts, are not intended to be
tially disassemble or assemble one part, then start on reinstalled after removal. Always use new replace-
another. Always recheck your work to assure that noth- ment hardware when installing locking fasteners.
ing has been overlooked. Do not make any adjustments,
other than those recommended, without obtaining 2. Use bolts of proper length. A bolt which is too long
proper approval. will bottom before the head is tight against its
related part. If a bolt is too short, there will not be
enough thread area to engage and hold the part
Pressure-Fit Parts properly. When replacing bolts, use only those
When assembling pressure-fit parts, use an anti-seize or having the same specifications of the original, or
molybdenum disulfide base compound to lubricate the one which is equivalent.
mating surface. 3. Unless specific torque requirements are given
within the text, standard torque values should be
Bearings used on heat-treated bolts, studs, and steel nuts, in
accordance with recommended shop practices.
1. When a bearing is removed, cover it to keep out (See Torque Chart Section 1.)
dirt and abrasives. Clean bearings in nonflamma-
ble cleaning solvent and allow to drip dry. Com- Hydraulic Lines and Electrical Wiring
pressed air can be used but do not spin the
bearing. Clearly mark or tag hydraulic lines and electrical wiring,
as well as their receptacles, when disconnecting or
2. Discard bearings if the races and balls (or rollers) removing them from the unit. This will assure that they
are pitted, scored, or burned. are correctly reinstalled.
3. If bearing is found to be serviceable, apply a light
coat of oil and wrap it in clean (waxed) paper. Do Hydraulic System
not unwrap reusable or new bearings until they 1. Keep the system clean. If evidence of metal or rub-
are ready to install. ber particles are found in the hydraulic system,
4. Lubricate new or used serviceable bearings before drain and flush the entire system.
installation. When pressing a bearing into a 2. Disassemble and reassemble parts on clean work
retainer or bore, apply pressure to the outer race. If surface. Clean all metal parts with non-flammable
the bearing is to be installed on a shaft, apply pres- cleaning solvent. Lubricate components, as
sure to the inner race. required, to aid assembly.
Gaskets Lubrication
Check that holes in gaskets align with openings in the Service applicable components with the amount, type,
mating parts. If it becomes necessary to hand-fabricate and grade of lubricant recommended in this manual, at
a gasket, use gasket material or stock of equivalent the specified intervals. When recommended lubricants
material and thickness. Be sure to cut holes in the right are not available, consult your local supplier for an
location, as blank gaskets can cause serious system equivalent that meets or exceeds the specifications
damage. listed.

Battery
Clean battery, using a non-metallic brush and a solution
of baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry battery and coat terminals
with an anti corrosion compound.

Lubrication and Servicing

Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart in Section
1.

31215074 2-3
 SECTION 2 - GENERAL

2.3 LUBRICATION AND INFORMATION Changing Hydraulic Oil

Hydraulic System 1. Use of any of the recommended crankcase or
hydraulic oils eliminates the need for changing the
1. The primary enemy of a hydraulic system is con- oil on a regular basis. However, filter elements
tamination. Contaminants enter the system by var- must be changed annually unless operating in
ious means, e.g., using inadequate hydraulic oil, extreme conditions. If it is necessary to change the
allowing moisture, grease, filings, sealing compo- oil, use only those oils meeting or exceeding the
nents, sand, etc., to enter when performing main- specifications appearing in this manual. If unable
tenance, or by permitting the pump to cavitate to obtain the same type of oil supplied with the
due to insufficient quantity of oil in supply tube. machine, consult local supplier for assistance in
selecting the proper equivalent. Avoid mixing
2. The design and manufacturing tolerances of the petroleum and synthetic base oils. JLG Industries
component working parts are very close, there- recommends changing the hydraulic oil annually.
fore, even the smallest amount of dirt or foreign
matter entering a system can cause wear or dam- 2. Use every precaution to keep the hydraulic oil
age to the components and generally results in clean. If the oil must be poured from the original
faulty operation. Every precaution must be taken container into another, be sure to clean all possible
to keep hydraulic oil clean, including reserve oil in contaminants from the service container. Always
storage. Hydraulic system filters should be replace the filter and clean magnet any time the
checked, cleaned, and/or replaced as necessary, at system oil is changed.
the specified intervals required in the Lubrication 3. While the unit is shut down, a good preventive
Chart in Section 1. Always examine filters for evi- maintenance measure is to make a thorough
dence of metal particles. inspection of all hydraulic components, lines, fit-
3. Cloudy oils indicate a high moisture content which tings, etc., as well as a functional check of each sys-
permits organic growth, resulting in oxidation or tem, before placing the machine back in service.
corrosion. If this condition occurs, the system must NOTE: Refer to section 4 for oil checking and oil changing
be drained, flushed, and refilled with clean oil. procedure.
4. It is not advisable to mix oils of different brands or
types, as they may not contain the same required Lubrication Specifications
additives or be of comparable viscosities. Good
grade mineral oils, with viscosities suited to the Specified lubricants, as recommended by the compo-
ambient temperatures in which the machine is nent manufacturers, are always the best choice, how-
operating, are recommended for use. ever, multi-purpose greases usually have the qualities
which meet a variety of single purpose grease require-
NOTE: Metal particles may appear in the oil or filters of new ments. Should any question arise, regarding the use of
machines due to the wear-in of meshing compo- greases in maintenance stock, consult your local sup-
nents. plier for evaluation. Refer to Section 1 for an explanation
of the lubricant key designations appearing in the Lubri-
Hydraulic Oil cation Chart.

1. Refer to Section 1 for recommendations for viscos-

ity ranges.
2. JLG recommends DTE11 hydraulic oil, which has
an SAE viscosity of 10W-30 and a viscosity index of
152.
NOTE: Start-up of hydraulic system with oil temperatures
below -15°F (-26°C) is not recommended. If it is nec-
essary to start the system in a sub-zero environment,
it will be necessary to heat the oil with a low density,
electrical heater to a minimum temperature of -15°F
(-26°C).

2-4 31215074
 SECTION 2 - GENERAL

2.4 CYLINDER DRIFT TEST 2.5 PINS AND COMPOSITE BEARING REPAIR
Maximum acceptable cylinder drift is to be measured GUIDELINES
using the following methods.
Filament wound bearings.

Platform Drift 1. Pinned joints should be disassembled and

inspected if the following occurs:
Measure the drift of the platform to the ground. Fully
a. Excessive sloppiness in joints.
elevate the platform. Maximum allowable drift is 2
inches (5 cm) in 10 minutes. If the machine does not b. Noise originating from the joint during opera-
pass this test, proceed with the following. tion.
2. Filament wound bearings should be replaced if
Cylinder Drift any of the following is observed:
a. Frayed or separated fibers on the liner surface.
Max. Acceptable Drift b. Cracked or damaged liner backing.
Cylinder Bore Diameter
in 10 Minutes
c. Bearings that have moved or spun in their
inches mm inches mm housing.
3 76.2 0.026 0.66 d. Debris embedded in liner surface.
3.5 89 0.019 0.48 3. Pins should be replaced if any of the following is
4 101.6 0.015 0.38 observed (pin should be properly cleaned prior to
inspection):
5 127 0.009 0.22
a. Detectable wear in the bearing area.
6 152.4 0.006 0.15
b. Flaking, pealing, scoring, or scratches on the
7 177.8 0.005 0.13 pin surface.
c. Rusting of the pin in the bearing area.
Drift is to be measured at the cylinder rod with a cali-
brated dial indicator. The cylinder oil must be at ambi- 4. Re-assembly of pinned joints using filament
ent temperature and temperature stabilized. wound bearings.
a. Housing should be blown out to remove all
The cylinder must have the normal load, which is the dirt and debris. bearings and bearing housings
normal platform load applied. must be free of all contamination.
If the cylinder passes this test, it is acceptable. b. Bearing/pins should be cleaned with a solvent
to remove all grease and oil. filament wound
NOTE: This information is based on 6 drops per minute cyl- bearings are dry joints and should not be lubri-
inder leakage. cated.
c. Pins should be inspected to ensure it is free of
burrs, nicks, and scratches which would dam-
age the bearing during installation and opera-
tion.

31215074 2-5
 SECTION 2 - GENERAL

2.6 PREVENTIVE MAINTENANCE AND The inspection and maintenance code numbers are as
follows:
INSPECTION SCHEDULE
1. Check for proper and secure installation.
The preventive maintenance and inspection checks are
listed and defined in the following table. This table is 2. Check for visible damage and legibility.
divided into two basic parts, the “AREA” to be inspected 3. Check for proper fluid level.
and the “INTERVAL” at which the inspection is to take
place. Under the “AREA” portion of the table, the various 4. Check for any structural damage; cracked or bro-
systems along with the components that make up that ken welds; bent or warped surfaces.
system are listed. The “INTERVAL” portion of the table is 5. Check for leakage.
divided into two columns representing the various
inspection time periods. The numbers listed within the 6. Check for presence of excessive dirt or foreign
interval column represent the applicable inspection material.
code for which that component is to be checked. 7. Check for proper operation and freedom of move-
The checks and services listed in this schedule are not ment.
intended to replace any local or regional regulations 8. Check for excessive wear or damage.
that may pertain to this type of equipment nor should
the lists be considered as all inclusive. Variances in inter- 9. Check for proper tightness and adjustment.
val times may occur due to climate and/or conditions
10. Drain, clean and refill.
and depending on the location and use of the machine.
11. Check for proper operation while pump/motor is
NOTICE running.
JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPEC- 12. Check for proper lubrication.
TION BE PERFORMED IN ACCORDANCE WITH THE "ANNUAL
13. Check for evidence of scratches, nicks or rust and
MACHINE INSPECTION REPORT" FORM.
for straightness of rod.
NOTE: This machine requires periodic safety and mainte- 14. Check for condition of element; replace as neces-
nance inspections by a JLG Dealer. Notify dealer if sary.
inspection is overdue.
15. Check for proper inflation.
16. Decals installed and legible.

2-6 31215074
 SECTION 2 - GENERAL

Table 2-2. Preventive Maintenance and Safety Inspection

AREA Interval
PRE-DELIVERY (a) ANNUAL (c)
OR FREQUENT (b) (YEARLY)
INSPECTION INSPECTION
PLATFORM
Controller 1,11 1,11
Switches 1,11 1,11
Placards and Decals 1,2 1,2
Control Tags 1,2 1,2
Hoses and Cables 4,8 4,8
Wear Pads 8,12 8,12
Handrails and Chains 1,4 1,4
Lanyard Anchorage Point 1,4,16 1,4,16
CHASSIS
Battery 3,5 3,5
Hydraulic Pump 1,5 1,5
Valves 1,5 1,5
Hydraulic Filter 26 26
Hydraulic Hoses and Tubing 1,5 1,5
Hydraulic Oil Tank 3,4,5 3,4,5
Lift Cylinder 1,4,5,6,12,13 1,4,5,6,12,13
Limit Switch 1,7 1,7
Tilt Alarm Switch 1,7 1,7
Placards and Decals 1,2 1,2
Wheel and Tire Assemblies 1,8,9 1,8,9
Drive Motors 1,5,6 1,5,6
Drive Brakes 1,6,8 1,6,8
Drive Torque Hubs 1,3,5,6 1,3,5,6
Steer Cylinder 1,4,5,6,13 1,4,5,6,13
Steer Components 1,4,6,8 1,4,6,8
Wheel Bearings 8,12 8,12
Scissor Arms 1,4 1,4
Safety Props 1,4 1,4
Sliding Wear Pads 8,12 8,12
Pivot Pins/Bolts 1,4,7,8 1,4,7,8
Switches, Ground Control 1,11 1,11
Control Tags 1,2 1,2

Footnotes:
(a) Prior to each sale, lease, or delivery
(b) In service for 3 months; or Out of service for 3 months or more; or Purchased used
(c) Annually, no later than 13 months from the date of the prior inspection

31215074 2-7
 SECTION 2 - GENERAL

2-8 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

SECTION 3. CHASSIS & SCISSOR ARMS

3.1 TRACTION SYSTEM will apply as little as 14A to the fields for higher rota-
tional speeds and better electrical efficiency.
Theory of Operation The Field Windings also provide direction reversal for
The Armatures (rotating windings) of the separately- traction. When driving forward, MOSFET switches 1 and
excited drive motors are wired in parallel to the Power 4 turn On to apply positive potential to F2 and ground
Module's -T and +B terminals (ZAPI) . The +B Terminal is potential to F1. In reverse, MOSFET switches 2 and 3
always at the same voltage as the +B (Battery Voltage turn On to apply positive potential to F1 and ground
when the Line Contactor is closed) and allows the mod- potential to F2. Theses switches are pulse-width modu-
ule t o measure current w it h the internal shunt lated by the Power Module to maintain a fixed relation-
(extremely low impedance). The -T Terminal is pulled to ship between Field and Armature Current (also called
Ground by the Armature Switch MOSFET's (connected the Field Map).
to -B Terminal). Since the two 24V Armatures are wired in parallel, the
To provide variable speed control, the Armature MOS- drive motors will attempt to rotate at the same speed
FET transistors switch On and Off at high frequencies under all conditions. If one wheel slips, the wheel with
(pulse-width modulation; 16kHz). The Duty Cycle (On & traction will demand more current as it slows slightly
Off time) is varied to control the voltage applied to the (under load). In this manner, the system provides effec-
Armatures. When the MOSFET's spend 50% of the tive traction control with no added complexity.
period On and 50% Off, approximately ½ of the avail- It is essential that the same amount of field current is
able Battery Voltage will be applied to the Armatures. supplied to both drive motors, or one wheel will pull the
Similarly, the MOSFET are On continuously (100% Duty vehicle (motor overheating and excessive tire wear
Cycle) to apply all available Battery Voltage to the Arma- would result). Independent field control would require a
tures (as in Driving at Full Speed). more complex Power Module, and parallel field wind-
Instead of permanent magnets, the separately-excited ings would require impedance matching. For simplicity,
drive motors use electro-magnets (called Field Wind- the vehicle uses 12V field windings wired in series to
ings) located in the stator (non-rotating) portion of the ensure proper distribution of current.
motor. Field windings are preferable to permanent mag- Two electrically-released parking brakes are mounted to
nets because the Power Module can adjust the stator's the rear of the drive motors. The Ground Module ener-
magnetism for optimum motor performance. When gizes the two 24V electro-magnets when appropriate to
climbing a grade a low speeds, the Power Module may allow vehicle motion. The parking brakes can be
apply as much as 40A to the field windings for more released electrically for emergency vehicle towing
electro-motive force. On level terrain, the Power Module

Line Contactor 24V

+ + + +

BF1 BF2 Right Field Winding

F2
T +B B

+ + Armature
F1
Left Right
Armature Armature MOSFET
Field
Shunt Left Field Winding
MOSFETS

Power Module

Figure 3-1. Traction Control Circuit - ZAPI Power Module

31215074 3-1
 SECTION 3 - CHASSIS & SCISSOR ARMS

3.2 PUMP/MOTOR - THEORY OF OPERATION Pump Motor Electrical Evaluation

The Power Module (see Figure 3-18., ZAPI Power Module Several basic electrical tests can be performed on the
Location on page 3-26) is essentially a "low-side" switch Pump Motor. Failure of one of these evaluations is signif-
for the pump motor. The positive terminal of the pump icant and may indicate that the device is physically dam-
is tied to Battery Positive after the Line Contactor. The aged.
negative terminal of the pump connects to the P Termi-
nal of the Power Module, which switches current Refer to Figure 7-2., Resistance Measurement. Make all
through MOSFET transistors to the Battery Negative. measurements with a voltmeter set to resistance scale
(Ohms). Disconnect the Main Battery Disconnect and all
For variable speed pump operation, the MOSFET transis-
pump motor cables during this analysis.
tors switch On and Off at high frequencies (16kHz). The
Duty Cycle is varied to control the voltage applied to the • Resistance < 5 Ohms between Motor Termninals.
pump motor. When the MOSFET's spend 50% of the The internal windings are very low impedance and
period On and 50% Off, approximately ½ of the avail- should appear to be a short-circuit for an ordinary
able Battery Voltage will be applied to the pump motor. voltmeter (other tests can determine if the windings
Similarly, the MOSFET are On continuously (100% Duty are truly shorted). High resistance can signal worn
Cycle) to apply all available Battery Voltage to the pump brushes, a faulty commutator, or open windings.
motor (as in Lift Up at full speed).
• Resistance > 1 MegaOhms between Motor Termi-
When the Control System is energized, the voltage at nals and Motor Housing. The internal windings
the P Terminal will be approximately +24V (referenced should be electrically isolated from the motor hous-
to -B) when the pump is static. The P Terminal will be ing. Low resistance may be an indication of a broken
approximately at +1V (referenced to -B) when the pump motor terminal, damaged brush, faulty commutator,
is running at full speed (Lift Up from Ground Mode). or burned winding.
Common Difficulties
The following difficulties can be examined using the JLG
Analyzer, a voltmeter, and simple hand tools. Unless other-
wise noted, the Control System shall be energized in
Ground Mode during testing. For a convenient Ground
Reference, place the black meter lead on the negative post
of the left battery in the left-side battery compartment.
The vehicle should be placed on a firm, level surface for all
analysis.

Line Contactor

+B

P 24V
Series DC
Pump Motor

-B

Power Module

3-2 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

1. Open-Circuit between +B Terminal and Pump brushes or broken terminals. After examination,
Motor Positive Terminal re-connect the Pump Motor Positive Terminal and
the Main Battery Disconnect.
This issue will allow the vehicle to drive, but Lift Up
and Steer Functionality will be lost and the Pump 4. Short-Circuit between Pump Motor Positive
Motor will not operate. Under DIAGNOSTICS - and Negative Terminals
PUMP, the JLG Analyzer will show PUMP PWM
This issue will allow the vehicle to drive, but Lift Up
100% and PUMP CUR 0.0A when Lift Up is oper-
and Steer Functionality will be lost and the Pump
ated from Ground Mode.
Motor will not operate. Under DIAGNOSTICS -
As shown in the diagram, the voltage measured PUMP, the JLG Analyzer will show an erratic read-
between the Pump Motor Positive Terminal and ing for PUMP PWM % and PUMP CUR will hover
Ground Reference should be 24V. If it is not, exam- around 150A when Lift Up is operated from
ine the cable between the terminal and the Power Ground Mode.
Module compartment. Inspect crimps for corro-
Pull the Main Battery Disconnect to completely
sion and ensure that bolted connections are tight.
de-energize the Control System. Next, detach both
Ensure that the cable is not crushed where it
Pump Motor Terminals and insulate them inde-
passes between the frame side sheets and the cyl-
pendently. Re-connect the Main Battery Discon-
inder assembly.
nect and re-try Lift Up. If the same symptoms
2. Open-Circuit between Pump Motor Negative persist (erratic PUMP PWM%, PUMP CUR around
Terminal and P Terminal 150A), examine the cabling between the Pump
Motor and Power Module compartment for a
This issue will allow the vehicle to drive, but Lift Up short-circuit (most likely near area where cylinder
and Steer Functionality will be lost and the Pump retracts between frame side sheets or near pot-
Motor will not operate. Under DIAGNOSTICS - hole mechanism). If the symptoms change, sus-
PUMP, the JLG Analyzer will show PUMP PWM pect a short-circuited (or mechanically frozen)
100% and PUMP CUR 0.0A when Lift Up is oper- pump motor.
ated from Ground Mode.
A clamp-on ammeter (set for 200A DC) can be
After ensuring there is not an Open-Circuit placed on either Pump Motor Cable for verifica-
between the +B Terminal and Pump Motor Posi- tion. During Lift Up, the ammeter will read approx-
tive Terminal, check that the voltage measured imately 150A.
between the Pump Motor Negative Terminal and
Ground Reference is 24V. If not, examine the issues
within Open-Circuit Pump Motor. This voltage
should ramp to approximately 0V when Lift Up is
operated from Ground Mode. If not, examine the
cable between the terminal and the Power Module
compartment (P Terminal). Inspect crimps for cor-
rosion and ensure that bolted connections are
tight. Ensure that the cable is not crushed where it
passes between the frame side sheets and the cyl-
inder assembly.
3. Open-Circuit Pump Motor
This issue will allow the vehicle to drive, but Lift Up
and Steer Functionality will be lost and the Pump
Motor will not operate. Under DIAGNOSTICS -
PUMP, the JLG Analyzer will show PUMP PWM
100% and PUMP CUR 0.0A when Lift Up is oper-
ated from Ground Mode.
Pull the Main Battery Disconnect to completely
de-energize the Control System. Next, detach the
cable from Pump Motor Positive Terminal. Using a
voltmeter set for resistance measurement (Ohms),
ensure that the resistance between the Pump
Motor Positive and Negative Terminals is less than
2 Ohms. If not, examine the pump motor for worn

31215074 3-3
 SECTION 3 - CHASSIS & SCISSOR ARMS

3.3 DRIVE MOTOR ELECTRICAL EVALUATION Common Traction System Difficulties

Several basic electrical tests can be performed on the 1. Short-Circuit Motor Armature
Drive Motors. Failure of one of these evaluations is sig-
This issue will allow the vehicle to drive very slowly
nificant and may indicate that the device is physically
or not at all. Rapid motor overheating (one motor)
damaged.
will result.
Refer to Figure 7-2., Resistance Measurement. Discon- This situation can be detected by elevating the
nect the Main Battery Disconnect and all drive motor vehicle's front wheels and engaging drive (plat-
cables during this analysis. form stowed). Under DIAGNOSTICS - TRACTION,
the JLG Analyzer's ARM CUR display (Armature
• Resistance < 2 Ohms Red to Black Armature Wires. Current Reading) will exceed 120A. The FLD CUR
The heavy red and black conductors are connected display (Field Current Reading) will hover around
to the motor's armature winding. The winding is a 40A. Neither wheel will rotate at normal speed, but
very low impedance and should appear to be a it will be possible to rotate the drive wheel by
short-circuit for an ordinary voltmeter. High resis- hand. The Power Module's self-diagnostics cannot
tance can signal corrosion, improper crimps, dam- detect this fault since the situation appears identi-
aged cabling, worn brushes, a faulty commutator, or cal to climbing a steep grade.
an open armature winding. To find the source of the difficulty, pull the Main
• Resistance < 2 Ohms Blue to Orange Field Wires. Battery Disconnect and disconnect the Armature
The blue and orange conductors are connected to Wiring (heavy red and black conductors) from the
the motor's field winding. In order to make this mea- suspected drive motor leading to the Power Mod-
surement, it will be necessary to disconnect the butt- ule's M1 and M2 Terminals. Re-test the traction
splice on the two orange wires or use a piercing function. If the remaining drive motor is able to
meter probe. As with the armature, the field is a very reach full speed (and Armature Current is less than
low impedance and should appear to be a short-cir- 50A), the drive motor that has been disconnected
cuit for an ordinary voltmeter. High resistance can is fault. Investigate for crushed and burned cables.
signal corrosion, improper crimps, damaged connec- Note if the drive motor smells burned.
tors, damaged cabling, or an open field winding.
2. Short-Circuit Brake Release
• Resistance 15-25 Ohms Yellow to Brown Brake
Wires. The yellow and brown wires are connected to This issue will not allow the vehicle to drive. Rapid
the integral brake. Improper resistance can signal motor overheating (both motors) will result. Con-
corrosion, improper crimps, damaged cabling, or a tinued attempts to drive the vehicle may result in
faulty solenoid. armature damage.

• Resistance > 1 MegaOhms Red Armature Wire to This situation can be detected by elevating the
Motor Housing. The armature winding should be vehicle's front wheels and engaging drive (plat-
electrically isolated from the motor housing. Low form stowed). Under DIAGNOSTICS - TRACTION,
resistance may be an indication of a crushed cable, a the JLG Analyzer's ARM CUR display (Armature
burned cable, or a burned armature winding. Investi- Current Reading) will exceed 120A. The FLD CUR
gate by disconnecting the drive motor cable from display (Field Current Reading) will hover around
the motor and re-measure resistance (isolation). 40A. Neither wheel will rotate, and it will be impos-
sible to rotate either drive wheel by hand. The
• Resistance > 1 MegaOhms Blue Field Wire to Ground Module cannot detect this fault during
Motor Housing. The field winding should also be power-up or self-test since energizing the brakes
electrically isolated from the motor housing. Low could pose a hazard. However, it may detect this
resistance may be an indication of a crushed cable, a issue during Drive (investigate using JLG Analyzer).
burned cable, or a burned field winding. Investigate
by disconnecting the drive motor cable from the To find the source of the difficulty, remove the rear
motor and re-measure resistance (isolation). cover from either drive motor. Insert voltmeter
leads into the white connector leading to the
• Resistance > 1 MegaOhms Red Armature Wire to brake solenoid (yellow and brown wires) and
Blue Field Wire. The armature and field windings attempt to drive (Platform Mode). The Ground
should also be electrically isolated from one another. Module will apply approximately 24V to the brake
Low resistance may be an indication of a crushed release solenoids (wired in parallel) during drive,
cable, a burned cable, damaged windings. Investi- but will reduce this voltage in the event of a short-
gate by disconnecting the drive motor cable from circuit. If this voltage is improper (less than 8V),
the motor and re-measure resistance (isolation). investigate using resistance measurement (refer to

3-4 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

Drive Motor Electrical Evaluation). Suspect dam- after power is disconnected to allow internal charge to
aged cabling, burned cabling, or faulty brake dissipate (risk of hazard, improper readings otherwise).
release solenoids. Trace the brake release cabling
• Resistance >100kOhms all Terminals to Housing.
from the Power Module Compartment to the
Ensure that there is an open-circuit between all ter-
Ground Module Connector J1-24.
minals of the Power Module and the module's alumi-
3. Open-Circuit Brake Release num housing. The device is fully potted and all
electronics are insulted from the housing. Place the
This issue will not allow the vehicle to drive. Rapid Black meter lead on the housing and use the Red
motor overheating (both motors) will result. Con- meter lead to probe all terminals.
tinued attempts to drive the vehicle may result in
armature damage. • Resistance < 2 Ohms between +B and M1. Ensure
that there is a short-circuit between the +B and M1
This situation can be detected by elevating the Terminals. Internally, there is a low-impedance cur-
vehicle's front wheels and engaging drive (plat- rent measurement shunt for the Armature portion of
form stowed). Under DIAGNOSTICS - TRACTION, Traction. Place the Red meter lead on +B, and the
the JLG Analyzer's ARM CUR display (Armature Black meter lead on M1.
Current Reading) will exceed 120A. The FLD CUR • Resistance >1 MegaOhms between F1 and -B; F2
display (Field Current Reading) will hover around and -B. Ensure that there is an open-circuit between
40A. It is possible that one wheel may rotate, or the two Field Terminals (F1 & F2) and -B. Internally,
neither may rotate (depending on the location of there are MOSFET transistors between these termi-
the open-circuit). Listen for the brake release sole- nals that should be high-impedance when the mod-
noid when activating drive. The Ground Module ule is un-powered. Place the Black meter lead on -B
cannot detect this fault during power-up or self- and the Red meter lead on F1 / F1.
test since energizing the brakes could pose a haz-
ard. However, it may detect this issue during Drive • Resistance >1 MegaOhms between F1 and +B; F2
(investigate using JLG Analyzer). and +B. Ensure that there is an open-circuit between
the two Field Terminals (F1 & F2) and +B. Internally,
If one wheel rotates, the open-circuit is located in there are MOSFET transistors between these termi-
the wiring for that specific drive motor (Power nals that should be high-impedance when the mod-
Module compartment or Drive Motor Cable). ule is un-powered. Place the Black meter lead on +B
Investigate for improper crimps, unlatched con- and the Red meter lead on F1 / F1.
nectors, damaged cables, or open brake release • Resistance >100kOhms between P and -B. Ensure
solenoids (refer to Drive Motor Electrical Evalua- that there is an open-circuit between the P and the -
tion). B Terminals. Internally, there are MOSFET transistors
If neither wheel rotates, the open-circuit is located between these terminals that should be high-imped-
in the wiring between the Power Module compart- ance when the module is un-powered. Place the
ment and Ground Module. Using a voltmeter, mea- Black meter lead on -B, and the Red meter lead on P.
sure the brake release voltage on either brake Note that a measurement of increasing resistance
connector in the Power Module compartment (capacitor charge) is normal, but a persistently low
during drive (should be approximately 24V). Inves- impedance is not.
tigate for improper crimps, unlatched connectors, • Resistance >1kOhms between M2 and -B. Ensure
damaged harnessing, or a faulty Ground Module. that there is an open-circuit between the M2 and -B
As an alternative, insert a short piece of wire with a Terminals. Internally, there are MOSFET transistors
Deutsch Female Crimp directly into Ground Mod- between these terminals that should be high-imped-
ule's J1-24 and measure voltage as a diagnostic ance when the module is un-powered. Place the
measure (eject vehicle harness from that pin). Black meter lead on -B, and the Red meter lead on
M2. Note that a measurement of increasing resis-
Power Module Electrical Evaluation tance (capacitor charge) is normal, but a persistently
low impedance is not.
Several basic electrical tests can be performed on the
• Resistance 120 Ohms between Pins 10 & 11.
Power Module. Failure of one of these evaluations is sig-
Ensure that the resistor that terminates the CANbus
nificant and may indicate that the device is physically
is within tolerance between pins 10 and 11 on the 12
damaged. If a Power Module is suspected to be faulty,
position Mini-Fit Jr (Connector "B"). Place the Red
thoroughly examine the rest of the system for possible
meter lead on pin 10, and the Black meter lead on pin
damage.
11. The resistance should measure between 110 - 130
Refer to Figure 7-2., Resistance Measurement. Discon- Ohms.
nect the Main Battery Disconnect and all cables from
the Power Module during this analysis. Wait 60 seconds

31215074 3-5
 SECTION 3 - CHASSIS & SCISSOR ARMS

3.4 TORQUE HUB Leak Test

The purpose of a leak test is to make sure the unit is air
NOTICE tight. You can tell if your unit has a leak if the pressure
THE PROCEDURES WITHIN THIS SEC TION APPLY TO ALL gauge reading on your leak checking fitting starts to fall
MACHINES AND TORQUE HUBS. PROCEDURES THAT APPLY TO after the unit has been pressurized and allowed to
SPECIFIC MACHINES AND TORQUE HUBS WILL BE SO NOTED BY equalize. Leaks will most likely occur at the pipe plugs,
PROPER SERIAL NUMBERS. the main seal or wherever o-rings are located. The exact
location of a leak can usually be detected by brushing a
NOTE: These instructions will cover how to completely soap and water solution around the main seal and
assemble and disassemble the Torque-Hub unit. where the o-rings or gaskets meet on the exterior of the
However, if the unit is under warranty you should unit, then checking for air bubbles. If a leak is detected
contact JLG Industries, Inc. for a replacement unit. in a seal, o-ring or gasket, the part must be replaced,
The warranty will no longer be valid if the unit is dis- and the unit rechecked. Leak test at 10 psi for 20 min-
assembled by non-JLG personnel. utes.
NOTE: Due to the small air volume inside this Torque-Hub, it
NOTICE will pressurize to 10 psi very quickly. If the pressure
TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK becomes excessive in the unit the seals will be
TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO MAKE destroyed.
SURE THAT THE UNIT’S GEARS AND SEALANTS ARE WORKING
PROPERLY. Oil Check/Fill Procedure
Torque-Hub units should always be roll and leak tested The torque hub unit is shipped with ISO 68 viscosity oil
before disassembly and after assembly to make sure (hydraulic fluid). It is designed to utilize the same oil
that the unit's gears, bearings and seals are working throughout its service life. However, should it need to
properly. The following information briefly outlines be checked/serviced use the following procedure.
what to look for when performing these tests. In the event of servicing, fill the unit with ISO grade 68
hydraulic oil (80W gear oil or 20W engine oil).
NOTE: The gearbox capacity is 10 oz of oil.
IF THE MACHINE IS ON ANY INCLINE, THE WHEELS MUST BE
ADEQUATELY BLOCKED PRIOR TO MANUALLY DISENGAGING 1. To check the oil level, rotate the wheel so that the
THE BRAKES. FAILURE TO DO SO MAY RESULT IN INJURY OR plugs in the cover are at 12 o-clock and 3 o-clock.
EVEN DEATH. 2. Allow the oil to settle than slowly remove the plug
at 3 o-clock.
NOTE: The brake must be released before performing the 3. If oil begins to come out the oil level is sufficient.
roll test. This can be accomplished by connecting the 4. If no oil is noticed at the 3 o-clock plug remove
brake release cable and depressing button. The brake both plugs.
can also be released by following the manual disen-
gage procedures outlined in this section. 5. Slowly add oil at the 12 o-clock plug location until
oil begins to seep out at the 3 o-clock plug loca-
tion.
CAUTION
6. Apply pipe dope or teflon tape to the cover plugs
RETURN BRAKE RELEASE CABLE BEFORE RETURNING TO NOR- and reinstall into the cover.
MAL OPERATION.
7. TIghten to 6 ft. lbs. - 8 ft. lbs. (8.4 Nm to 11.2 Nm).

Roll Test
The purpose of the roll test is to determine if the unit's
gears are rotating freely and properly. You should be
able to rotate the wheel or hub of the gearbox by hand.
If you feel more drag in the gears only at certain points,
then the gears are not rolling freely and should be
examined for improper installation or defects. Some
gear packages roll with more difficulty than others. Do
not be concerned if the gears in your unit seem to roll
hard as long as they roll with consistency.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Brakes - Manual Disengage Procedure

1. Brake Cover 3. Disengage Holes

2. Cover Bolts

Figure 3-2. Disengage Procedure

1. Chock wheels or secure machine with tow vehicle.

CAUTION
2. Ensure battery disconnect switch is in to the "OFF"
position. AFTER THE MACHINE IS TOWED, THE DISENGAGE BOLTS MUST
3. Remove the two Cover Bolts and Brake Cover.
BE REMOVED FROM THE BRAKE DISENGAGE HOLES. THE
BRAKES CANNOT BE ENGAGED WITH THE DISENGAGE BOLTS IN
4. Insert the Cover Bolts into the two Disengage THE BRAKE DISENGAGE HOLES. THIS WILL CAUSE THE MACHINE
Holes in the brake housing. TO ROLL WHEN PARKED ON AN INCLINE.
5. Tighten down the Cover Bolts and the brake on
that drive motor will disengage.
6. Repeat this procedure on opposite wheel drive.
With both drive motor brakes now disengaged,
the machine can be moved manually.
7. After towing is complete, chock wheels and
remove Cover Bolts from Disengage Holes.
8. Reinstall Brake Cover.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Drive Motor Removal

1. Drive Motor 3. Washers

2. Motor Mounting Bolts 4. Motor Cable

Figure 3-3. Motor Removal

3. Remove the two motor mounting bolts and wash-

CAUTION ers.
ENSURE THE BATTERY DISCONNECT SWITCH IS IN THE OFF 4. Gently remove the drive motor (1).
POSITION BEFORE REMOVING DRIVE MOTOR.

1. Disconnect the motor cable from the power con-

trol module.
2. Drain the oil out of the unit by removing the cover
plug. Note the condition of the oil, replace if nec-
essary.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Main Gearbox Disassembly

1. Spindle Sub-Assembly 5. Cover O-Ring 9. Pipe Plug

2. Spiral Snap Ring 6. Cover Thrust Washer 10. Input Carrier Sub-Assembly
3. Input ring Gear 7. Cover 11. Hub Sub-Assembly
4. Input Sun Gear 8. Cover Snap Ring

Figure 3-4. Main Gearbox Disassembly

1. Using a screwdriver, pry off the cover snap ring. NOTE: The input ring gear is held in with a press fit on its
2. Remove cover. Cover Thrust washer should be in outside diameter. Insert jacking screws (1/4-20UNC
the inner counterbore of the cover. grade 8) with at least 1.5 inches of thread length into
each of the three tapped holes to force the ring gear
NOTE: To grip the cover for removal a pipe may need to be out. Be sure and alternate between the jacking
inserted into the pipe plug holes. screws to keep the ring gear from becoming mis-
3. Remove input sun gear. aligned in the bore. The screws will push against the
outer race of the main bearing. This bearing will have
4. Remove input carrier sub-assembly. to be replaced afterwards.
5. Remove cover o-ring.
7. Using a screwdriver remove spiral snap ring.
6. Remove input ring gear.
8. Pull hub sub-assembly off of the spindle sub-
assembly.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Input Carrier Disassembly

1. Planet Gears 4. Thrust washer 7. Thrust Plate

2. Output Sun Gears 5. Input Planet Gear 8. Snap Ring
3. Input Carrier 6. Needle Bearings 9. Retaining Ring

Figure 3-5. Input Carrier Disassembly

1. Remove retaining rings from each of the 3 planet NOTE: The planet pins are held in with a press fit. To avoid
shafts. damage to the parts, use an arbor or hydraulic press
to remove the planet pins.
NOTE: Do not overstress these retaining rings when remov-
ing them.
2. Remove thrust plate.
3. Remove a thrust washer from each planet shaft.
4. Slide each input planet gear off the planet shaft.
5. Remove 22 needle bearings from the bore of each
planet gear.
6. Remove the thrust washer from each planet gear.
7. Remove retaining ring from output sun gear.
8. Slide output sun gear out from the center of the
input carrier.
9. Remove the three planet shafts from the input car-
rier.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Hub Disassembly

1. Seal
2. Hub
3. Main Bearing

Figure 3-6. Hub Disassembly

1. Remove main wheel bearing. 2. Remove main lip seal.

NOTE: This part is held in the hub with a press. To remove NOTE: This lip seal is also held in with a press fit. Remove
have the hub sitting seal side up. Use a plate or rod the lip seal only if the hub or seal needs to be
with a large enough diameter push in the inner race replaced. The lip seal will most likely become dam-
of the bearing. Apply force to the push the bearing aged during removal. Try not to damage the hub
out. This bearing will need to be replaced upon reas- bore.
sembly.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Spindle Disassembly

1. Spindle Sub-Assembly 5. Thrust Washer 9. O-Ring

2. Main Bushing 6. Output Planet Gear 10. Shaft Seal
3. Shaft Ball Bearing 7. Output Planet Pins 11. Snap Ring
4. Tanged Washer 8. Main Bearing 12. Needle Roller Bearings

Figure 3-7. Spindle DIsassembly

1. Place unit on bench with planet gears facing up. 6. Press out the motor shaft seal from the center
2. Remove 3 output planet shafts. bore.
7. Remove the main bearing from the outside diame-
NOTE: These planet shafts are held in with a press fit. Use ter of the spindle.
the tapped hole in the end of the pin in conjunction
with a slide hammer or similar tool to remove them. NOTE: This bearing is held in with a press fit. You will need to
pry against the spindle to remove it. The bearing will
3. Remove the output planet gear, thrust washer, and need to be replaced when this is done.
tanged washer out of each gear “window” of the
spindle. 8. Press out the main bushings at the top of the spin-
dle neck.
NOTE: The output planet gears are a very similar size to the
input planet gears, tag or label the planet gears to 9. Remove the motor O’ring from the groove on side
avoid confusion. opposite from the carrier side.

4. Using a screwdriver remove the shaft bearing snap

ring.
5. Remove the shaft ball bearing from the center
bore.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Spindle Sub-Assembly 7. Place tanged thrust washer into each planet “win-
dow” of the spindle. Make sure the tang sits in the
1. Using an appropriate pressing tool, press in the 2 cast groove on the inside of the window.
main bushings in the upper bore of the spindle. 8. Place a thrust washer onto the plane gear. Line up
The lower bushing needs to be flush with the bot- the bores as best as you can. Use grease to hold
tom of the bore and the upper bushing needs to the thrust washer in place.
be flush with the bottom of the bore.
9. Slide the planet gear into the window with the
2. Using the clevis pin from the steering linkage or an tanged washer until the bores line up.
M12 bolt, drive the flanged steer link bushing into
the appropriate spindle ear hole. If the wheel drive 10. Insert an output planet pin into the planet pin
is for the left wheel then, with the carrier side up hole of the spindle and through the bores of the
and kingpin bore oriented to the top, put the steer thrust washers and the planet gear.
link bushing in the left ear. 11. Before pressing the planet pin into the spindle
3. Using the appropriate pressing tool, press on main make sure the gear spins freely.
bearing until it is fully seated. 12. Press the planet pin into the spindle until it bot-
4. Insert the motor shaft bearing into the center bore toms out. Make sure the planet gear turns freely
of the spindle. The bearing is a slight slip fit, but it after the planet pin is pressed in.
may require some press to assemble if the bearing 13. Repeat Steps 6-12 for the other two output planet
becomes misaligned. gears.
5. Retain the bearing with the spiral retaining ring. 14. Turn the spindle over so that the carrier is down.
6. Line the bore of the output planet gear with 22 15. Using a flat plate or rod, press the motor shaft seal
needle rollers. Use grease to retain the needle roll- into the center bore so that it is flush with the face
ers in the bore. of the spindle.
16. Grease and install the motor O’ring into the
groove.

CARE SHOULD BE TAKEN TO PREVENT ANY OIL FROM MAKING

CONTACT WITH THE BRAKE DISCS. IF THIS OCCURS IT WILL
DEGRADE THE BRAKES PERFORMANCE.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Hub Sub-Assembly

1. Seal
2. Hub
3. Main Bearing

Figure 3-8. Hub Disassembly

1. Put hub on a table with the tapped holes facing 3. Flip the hub over.
down. 4. Using an appropriate pressing tool, press the main
2. Using a flat plate in conjunction with a pressing bearing into the bore until it bottoms out.
tool, press in the seal so it is flush with the edge of
the hub.
NOTE: The seal has a thin outer shell that can be easily dam-
aged if not installed with care. It is a good idea to
start the seal into the bore with a rubber mallet
before pressing.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Input Carrier Sub-Assembly

1. Planet Gears 4. Thrust washer 7. Thrust Plate

2. Output Sun Gears 5. Input Planet Gear 8. Snap Ring
3. Input Carrier 6. Needle Bearings 9. Retaining Ring

Figure 3-9. Input Carrier Disassembly

1. Press 3 input planet shafts into the 3 holes of the visually. Additional grease may help hold every-
input carrier. The head of the input planet shaft thing together.
needs to sit flush in the counterbore of the input 6. Place the input planet gear and thrust washers
carrier hole. onto the input planet shaft sticking out from the
2. Insert output sun gear into the splined bore of the carrier. When you slide the input planet shafts into
input carrier. The gear tooth end of the output sun the bores, the needle bearings will try to push out.
gear should protrude in the opposite direction of If you have the thrust washers lined up properly
the input planet shaft. they will contain the needle bearings within the
3. Using retaining ring pliers. Install the retaining ring input planet-gear.
into the groove of the output sun gear. Make sure 7. Repeat 5 & 6 for the other 2 planet gears.
that the ring is correctly seated in the groove and 8. Put the thrust plate onto the three input planet
that the output sun gear cannot be pulled out of shafts. Use the 3 holes on the innermost bolt circle.
the input carrier. The other 3 holes are for a different gear ratio.
4. Load 22 needle rollers into the bore of each input 9. Using the appropriate retaining ring pliers put a
planet gear. Retain the needle bearings in the bore retaining ring into the groove of each planet shaft.
with a coating of grease.
NOTE: Do not overstress the snap ring.
5. Place a thrust washer on each side of the input
planet gear. Line up the bores as well as you can

31215074 3-15
 SECTION 3 - CHASSIS & SCISSOR ARMS

Main Gearbox Assembly

1. Spindle Sub-Assembly 5. Cover O-Ring 9. Pipe Plug

2. Spiral Snap Ring 6. Cover Thrust Washer 10. Input Carrier Sub-Assembly
3. Input ring Gear 7. Cover 11. Hub Sub-Assembly
4. Input Sun Gear 8. Cover Snap Ring

Figure 3-10. Main Gearbox Disassembly

1. Inspect seal surface of spindle. Remove any debris b. Stage 2: Find the planet gear that is tight and
that may be present. turn it until you feel it go into mesh with the
2. Apply a coating of grease to the lip seal of the hub hub gear teeth, apply slight downward pres-
sub-assembly. sure to the hub and then find the next gear
that is tight and do the same.
3. Place Spindle Sub-Assembly on table with carrier
side up. c. Stage 3: Once all the planet gears are in mesh
apply pressure to the hub, it should go on the
4. Carefully install the hub sub-assembly (seal side rest of the way.
down) onto the spindle. This installation should be
a slip fit and takes place in 3 stages. 5. Install retaining ring into the groove on the OD of
the spindle carrier. This is a spiral retaining ring so
a. Stage 1: The hub slides together until the gear it will not require pliers. You will need to pull the
teeth of the hub hit the gear teeth of the 3 out- retaining ring apart and work it into the groove.
put planets.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

6. Using an appropriate pressing tool, press the Input 10. Apply a heavy coating of grease to the cover thrust
Ring gear (recessed side down) into the hub sub- washer and place it in the center counterbore of
assembly. the cover. The grease will help keep it in the bore
during assembly.
NOTE: Do not use excessive pressing force because it will be
reacted by the main wheel bearings. 11. Center the cover in the hub bore so that the “JLG”
logo is up. Push it into the bore.
7. Install the input carrier sub-assembly into mesh.
The output sun portion of the sub-assembly will NOTE: Do not hit the cover with a hammer or mallet, shocks
mesh with the output planet gears and the planet may cause the cover thrust washer to dislodge and
gears mounted on the sub assembly will mesh drop into the gear cavity prior to the cover getting
with the input ring gear. positioned properly. If all the parts are to size and
assembled properly, the cover should not need exces-
8. Install the input sun gear into the area between
sive force to assemble.
the 3 input planet gears.
9. Apply a coating of grease to the cover o’ring and 12. Install the cover retaining ring into the hub
install it into the o’ring groove of the hub. groove.
NOTE: It may be helpful to stretch the o’ring out prior to
assembly to avoid pinching or shearing when the
cover is assembled.

31215074 3-17
 SECTION 3 - CHASSIS & SCISSOR ARMS

Motor and Brake Assembly

1. Drive Motor 3. Washers

2. Motor Mounting Bolts 4. Motor Cable

Figure 3-11. Drive Motor Assembly

1. Insert the drive motor into the back of the gear- 3. Connect the end of the Motor Cable to the Power
box. The drive motor will pilot on the four bosses Module.
in the gearbox. Try to keep the end of the motor 4. Fill the gearbox with oil ISO grade 68 oil or oil of a
shaft from causing damage to the lip seal in the similar viscosity (80W gear oil or 20W engine oil).
gearbox. The gearbox will need to be filled with 10 oz of oil.
NOTE: The motor may need to be rotated to line up the sun
gear splines with the motor shaft splines.
2. Install the two motor mounting bolts and washers.
Torque to 9 - 11 ft. lbs. (12 - 15 Nm).

3-18 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme
care should be taken to ensure that the bolts are not
tightened beyond their specified torque.
The following steps describe how to tighten and torque
bolts or socket head capscrews in a bolt circle.
1. Tighten (but do not torque) bolt "A" until snug.
2. Go to the opposite side of the bolt circle and
tighten bolt "B" until equally snug.
3. Crisscross around the bolt circle and tighten
remaining bolts.
4. Now use a torque wrench to apply the specified
torque to bolt "A".
5. Using the same sequence, crisscross around the
bolt circle and apply an equal torque to the
remaining bolts.

BOLT A

Figure 3-13. Assembly Tool 2

BOLT B

Assembly Tools

Figure 3-14. Assembly Tool 3

Figure 3-12. Assembly Tool 1

31215074 3-19
 SECTION 3 - CHASSIS & SCISSOR ARMS

3.5 DRIVE MOTOR CABLE ROUTING 4. Place the Green Clamp on the clamping rings as
shown below.
1930ES Only
CAUTION
BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS
BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR
CABLING.

1. Orient the drive cables going back towards the

rear of the machine as shown below.

5. Bolt the clamp onto the underside of the frame.

a. The Spacer goes between the frame and the
Clamp.
b. Place the Larger Washer against the clamp.
6. Connect the drive motor cables to the power mod-
ule.
7. Tuck all wires into the power module compart-
ment and install cover.

2. Loop the cables forward towards the front of the 1 3 2 1

machine then up and back so that the clamping
rings on the cables are aligned together.
3. Obtain the Cable Clamp and hardware.

1. Drive Cables
1. Cable Clamp 3. Capscrew, Washers, and 2. Cable Clamp
2. Spacer Plate Nut 3. Spacer Plate

8. Reconnect battery cable plug. Power up machine

and operate the drive function to ensure drive
motors operate properly.

3-20 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

2032ES/2632ES/2646ES/3246ES Only
CAUTION
BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS
BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR
CABLING.

1. Orient the drive cables going back towards the

rear of the machine. Loop the cables forward
towards the front of the machine then up and
back. Place the Green Clamp on the clamping ring
as shown below.

1. Drive Cable 3. Cable Clamp

2. Roll Pin
2. Obtain the Cable Clamp and hardware.
NOTE: When bolting the green clamp onto the frame, place
the larger washer against the clamp on the outside
of the clamp.
4. Connect the drive motor cables to the power mod-
ule.
5. Tuck all wires into the power module compart-
ment and install cover.
6. Reconnect battery cable plug. Power up machine
and operate the drive function to ensure drive
motors operate properly.

1. Bolt, Washers, and Nut

2. Cable Clamp
3. Bolt the Green Clamp onto the backside of the
frame using the the back hole drilled in step #4.
The roll pins inserted in the front-most holes act as
a stop to prevent the clamp from turning.

31215074 3-21
 SECTION 3 - CHASSIS & SCISSOR ARMS

3.6 ELECTRIC DRIVE MOTOR SERVICE

1. Wire Harness 7. Retaining Ring 13. Cover Plate Kit

2. Frame & Field Assembly 8. Bearing 14. Cover Plate Mounting Screws
3. Armature Assembly 9. Commutator End Head 15. Brake Cover Mounting Screws
4. Brush Spring 10. Grommet 16. Terminal Cover Mounting Screws
5. Brush & Terminal Assembly 11. Brake Assembly
6. Brush Box Assembly 12. Gasket Seal Kit

Figure 3-15. Drive Motor Components

3-22 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

NOTE: Reference Figure 3-15., Drive Motor Components for 4. Using a dielectric tester, verify that there are no
part names and locations when servicing the Drive shorts between the following items:
Motor. a. Field connector pins and the case of the motor.
Periodic maintenance consisting of inspections of b. Armature terminals and the case of the motor.
motors, batteries and wiring circuitry is recommended. c. Field connector pins to the armature terminals.
5. Verify continuity in 2 pin brake connector (yellow
CAUTION and brown wires). Measure the brake resistance
ALWAYS WEAR EYE PROTECTION DURING ANY MAINTENANCE and verify that it is between 18 and 22 Ohms.
OPERATION.
Drive Motor Disassembly
Servicing Guidelines NOTE: Refer to Figure 3-15.
Since the operating environment of industrial equip- 1. Remove the two Cover Plate Mounting Screws (14)
ment varies widely, the following are suggested for peri- holding the Cover Plate (13) in place and remove
odic maintenance inspection intervals. the cover plate from the motor.
• Normal Service – Perform routine inspection (out- 2. Remove the Brake Cover Mounting Screws (15)
lined in the Inspection and Service portion of this holding the Brake (11) in place and set aside. These
section) every 1,000 hours of drive time. screws are used to manually release the brakes.
• Severe Service – Perform routine inspection every 3. Remove the two Terminal Cover Mounting Screws
500 hours of drive time. Severe service environments (16). Slide the strain relief of the Wire Harness (1)
are listed below: out of the cover and remove the cover from the
motor.
a. Dusty or dirty locations like cement plants, 4. Discard the Gasket (12) that was located under the
lumber and flour mills, coal mining, stone brake and terminal covers.
quarries, etc.
5. Remove the wire harness from the motor by dis-
b. High temperature areas like steel mills, found- connecting the brake connection and armature
ries, etc. connections. Cut the field connection close to the
c. Environments with sudden temperature crimp connection on the motor side.
change, such as in refrigeration plant, etc. 6. Install the two Brake Cover Mounting Screws (15)
into the threaded holes in the brake assembly and
Drive Motor Troubleshooting tighten to manually release the brake (see Figure
1. Turn off power to unit and disconnect main bat- 3-3.).
tery power. Disconnect drive motor connections 7. Remove the three screws holding the brake
from the Power Module. assembly to the motor. Carefully remove the brake
2. Verify field continuity between the blue and assembly, brake disc and reaction disc from the
orange wires. If available, use a 4-wire ohmmeter motor by sliding off of the shaft.
to verify the field resistance per the applicable 8. Remove the screws holding the Commutator End
motor specification below. Head (9) in place and remove the commutator end
3. Verify armature continuity between the red and head from the frame and field assembly. The
black wires. If available, use a 4-wire ohmmeter to Armature (2) will be attached to the commutator
verify the field resistance per the applicable motor end head.
specification below. 9. Pull back the Brush Springs (4) in the commutator
end head, pull the brush back and rest the springs
Field Resistance @ Armature Resistance on the side of the brush. The brushes should move
Model freely within the holders.
75°F (24°C) @ 75°F (24°C)
10. Use an arbor press or a bearing puller to remove
1930ES 0.21 Ohms 0.037 Ohms the armature from the commutator end head
assembly.
2032ES/2632ES/2646ES/
0.127 Ohms 0.051 Ohms 11. Remove the Snap Ring (7) and Bearing (8) from the
3246ES
commutator end head. Discard the bearing.

31215074 3-23
 SECTION 3 - CHASSIS & SCISSOR ARMS

Drive Motor Inspection and Service Drive Motor Reassembly

NOTE: Refer to Figure 3-15. NOTE: Refer to Figure 3-15.
1. Carefully blow out any accumulated carbon dust 1. After inspection and servicing, reassemble the wir-
and dirt from the Commutator End Head (9) and ing in the Commutator End Head (9) as originally
the Frame & Field Assembly (2) using clean, oil free, found. Ensure the wiring does not contact metal
compressed air. parts and that it allows the brushes to move unre-
2. Replace Brushes (5) that are worn below their stricted in the holders. Motor terminals must be
usable length of 0.6 in (1.5 cm), show signs of assembled as shown Figure 3-16. Torque bottom
uneven wear or signs of overheating, such as dis- terminal nut to 110 - 140 in-lb (12.4 - 15.8 Nm).
colored brush shunts and brush springs. Brushes 2. After the motor has been disassembled, it is rec-
should always be replaced in complete sets of four. ommended that new bearings be installed
Use identical replacement parts; do not substitute because bearings may have been damaged during
brush grades as the brushes are matched to the removal. Although the bearings may appear and
motor type and application to provide the best feel good, the bearing races could be “brinelled”
service. Substituting brushes of the wrong grade (races or balls deformed) and may exhibit noise
can cause premature commutator failure and and vibration problems or fail within a relatively
excessive brush wear. short period of service. Press a new bearing into
3. Make sure the Brush Box Assembly (6) is tight on the commutator end head, pressing on the outer
the commutator end head. Replace brush box race only. See Figure 3-16. Replace the Retaining
assemblies in the commutator end head if they are Ring (7) in the retaining ring groove.
physically damaged or brush holders are loose on 3. Press the Armature (3) commutator end into the
the brush plate. commutator end head and bearing assembly,
4. Visually inspect the frame and field assembly for carefully supporting the inner-race of the bearing.
overheating or other signs of damage. Check all See Figure 3-16.
wiring to ensure that the insulation is in good con- 4. Carefully release the Brush Springs (4) allowing the
dition. Verify that pole screws are torqued to 250 - Brushes (5) to contact the commutator. Make sure
300 in-lb (28.2 - 33.9 Nm). Verify field resistance brush shunts do not interfere with spring move-
using a suitable ohmmeter per the appropriate ment.
motor specification. Verify that the field is electri-
cally isolated from the frame using a dielectric tes-
ter. Replace as necessary.
5. Visually inspect the Armature Assembly (3) for
signs of overheating or physical damage. Visually
inspect the seal surface of the shaft for excessive
wear. Check for grounded circuits using a dielec-
tric tester by applying voltage between the com-
mutator and the shaft. Visually inspect the
commutator for excessive wear and overheating.
Replace as necessary.
6. Visually inspect the brake surfaces for excessive
wear. Replace Brake Assembly (11) if necessary.
7. Visually inspect the Wire Harness (1) for frayed
insulation, loose terminals, or other damage.
Replace as necessary. 1. Press Fixture must press against Outer Race
2. Bearing
3. End Head (held stationary)
4. Armature Assembly
5. Assembled End Head, Bearing, and Retaining
Ring
6. Press Fixture must press against Inner Race (held
stationary)

Figure 3-16. Bearing Pressure Guidelines

3-24 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

5. Assemble the commutator end head to the Frame 7. Install Wire Harness (1) to motor by connecting the
& Field Assembly (2) and tighten the screws to 120 brake connectors and securing the armature ter-
- 140 in-lb (13.6 - 15.8 Nm). Make sure to align the minals to the terminal studs. Crimp the field con-
field connection with the notch in the commuta- nection (red/orange to orange and blue to blue)
tor end head. Seal wires where they exit from com- together and heat shrink. Motor terminals must be
mutator end head with the Grommet (10). assembled as shown in Always secure the bot-
6. Place the Gasket Seal (12) in the bottom of the tom nut with a wrench as you tighten the top
notch in the commutator end head. Align wires nut. Torque top nut to 90 - 110 in-lb (10.2 - 12.4
from the Brake Assembly (11) into the notch in the Nm).
commutator end head. Secure brake assembly to 8. Remove manual release screws from brake assem-
commutator end head using three bolts. bly. Apply new Gasket (12) and affix brake cover to
motor using the 2 manual release screws.
9. Attach terminal cover to the commutator end
head using two terminal cover screws.
10. Slide the strain relief of the wire harness into the
slot of the terminal cover. Align cover plate with
groove in frame and field and affix using two cover
plate screws.

Figure 3-17. Wire Harness Connections

31215074 3-25
 SECTION 3 - CHASSIS & SCISSOR ARMS

3.7 POWER MODULE - ZAPI

MACHINE FRONT

ZAPI POWER MODULE

Figure 3-18. ZAPI Power Module Location

.
1. Turn machine power off and disconnect the bat-
Table 3-1. ZAPI Power Module Specs teries.
2. Locate and remove the power module protective
Operating Voltage ( B+) 14.5 to 40 VDC cover from the machine.
Maximum Current Limits: 3. Note the wire terminal locations when removing
Armature 300 A the old power module.
Field 40 A 4. Disconnect all wire connectors and cables from
Pump 180 A the old power module and remove it from the
Standby Current 150 mA machine.
5. When installing the new power module, be sure
Temperature Range:
that the terminals are oriented as shown in Figure
Operating -40°C to 75°C
3-18.
Storage -40°C to 125°C
Thermal Limit 75°C to 90°C 6. After installing the new power module, begin con-
necting the wire connectors/cables to the module.
Switching Frequency 16 kHz
7. Torque all terminal bolts to torque specifications
shown on the front of the module.
The power module is located behind a protective cover
8. After all connections to the power module are
at the front of the machine as shown in Figure 3-18.,
made, the batteries can be reconnected.
ZAPI Power Module Location. Use the following instruc-
tions when replacing the power module. 9. Reinstall the power module cover, then check for
normal machine operation.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

ZAPI Power Module Electrical Evaluation

INTEGRATED HEALTH INDICATOR "HEALTH"
(STATUS LED)
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. It should be noted that this will trigger
replacement of the device.

PN - 1001092456
ZAPI Power Module - "HEALTH" (Status LED)

31215074 3-27
 SECTION 3 - CHASSIS & SCISSOR ARMS

3.8 MDI (MULTIFUNCTION DIGITAL INDICATOR) 3. Apply di-electric grease to the two Brake Release
Plugs. Connect the Brake Release Plugs to the
AND BRAKE RELEASE Brake Release Button on the backside of the
mounting bracket.
NOTE: The brake release plugs have no polarity, therefore,
can be connected to either post on the button.
4. Connect the MDI harness to the Diagnostic Port.

MDI and Brake Release Bracket

Installation:
NOTICE
ENSURE EMS BUTTONS ON THE CONTROL STATIONS ARE
PUSHED IN TO THE OFF POSITION BEFORE CONNECTING AND
MOUNTING THE MDI AND BRAKE RELEASE BRACKET.
1. MDI Connected
1. Open the Battery Cover on the right side of the 2. Brake Release Connected
machine (ground control station side). Lifting up
on the battery tray and pulling out will allow for
maximum extension.
2. Locate the Diagnostic Port (1) and Brake Release
Plugs (2).

1. Diagnostic Port
2. Brake Release Plugs

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 SECTION 3 - CHASSIS & SCISSOR ARMS

5. Using a 5/32" allen wrench, mount the MDI and 6. Using zip ties, tie back cables and wires to prevent
Brake Release Bracket onto the wall of the battery damage to the cables and wires.
compartment. (appropriate mounting holes are
pre-existing) Apply medium strength threadlock-
ing compound to the screws and torque to 3.6 ft-
lb (5 Nm). (Refer to Figure 3-19.)

3 2
1

Removal:
NOTICE
ENSURE EMS BUTTONS ON THE CONTROL STATIONS ARE
PUSHED IN TO THE OFF POSITION BEFORE DISCONNECTING THE
1. MDI & Brake Release Bracket MDI AND BRAKE RELEASE BRACKET.
2. Screw, M5 x 16
3. Washer, 5mm 7. Remove the two Screws (2) and Washers (3).
8. Disconnect Brake Release and MDI from the elec-
Figure 3-19. MDI Installation/Removal trical harnesses.
9. Remove Bracket.
5. Power machine and check to ensure LEDs on MDI
work. Check to ensure Brake Release Button works.
If the Software Version is not P1.13 or higher,
"Error" will display on the LCD. If a fault exists, the
trouble code will display on the LCD. (Refer to Sec-
tion 6.)

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 SECTION 3 - CHASSIS & SCISSOR ARMS

3.9 BATTERY REMOVAL 4. Adjust the lifting device to take the weight of the
battery door and remove door from under the
machine.
NOTICE
5. Once the battery door is removed from the
JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS machine, battery replacement/maintenance can
ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC- begin.
TORY APPROVED BATTERIES.
6. After any maintenance on the batteries or replace-
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE ment of the batteries is complete lift the battery
THROUGH JLG'S AFTERMARKET PARTS DISTRIBUTION CENTERS door back onto the machine.
OR JLG'S AFTERMARKET PROGRAMS. FOR ASSISTANCE WITH 7. Make sure the rollers are replaced and tight.
PROPER BATTERY REPLACEMENT, PLEASE CONTACT YOUR 8. Reconnect batteries and check for proper opera-
LOCAL JLG SUPPORT OFFICE. tion.

BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COMPAT-

IBILITY WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q
BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE
CYCLE TIMES. THE USE OF NON APPROVED BATTERIES IN YOUR
JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR
BATTERY CHARGER FAULT CODES. JLG ASSUMES NO RESPONSI-
BILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM
THE USE OF NON APPROVED BATTERIES.

BEFORE BATTERY REMOVAL CAN BEGIN, ENSURE THAT THE

BATTERIES HAVE BEEN PROPERLY DISCONNECTED TO AVOID
SERIOUS INJURY OR POSSIBLE DEATH.

1. Pull the battery door completely out and discon-

nect the batteries.
2. Rest the battery door onto the forks of a fork truck,
or suitable lifting device. Be sure the forks or lifting
device are properly centered over the weight of
the battery door.
3. Using a phillips screwdriver, remove the battery
door rollers located at the rear corners of the bat-
tery door.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Battery Maintenance and Safety Practices 3.10 BATTERY CHARGER

The Battery Charger is located on the top of the chassis
CAUTION at the rear of the machine. Raise and secure scissor arms
ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT with arm prop to gain access to the charger.
WITH SKIN OR CLOTHING. WEAR PROTECTIVE CLOTHING AND
EYEWEAR WHEN WORKING WITH BATTERIES. NEUTRALIZE ANY
BATTERY ACID SPILLS WITH BAKING SODA AND WATER.

BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING,

ALLOW NO OPEN FLAMES, SPARKS OR LIGHTED TOBACCO PROD-
UCTS IN THE AREA WHILE CHARGING BATTERIES. CHARGE BAT-
TERIES ONLY IN A WELL VENTILATED AREA.

ADD ONLY DISTILLED WATER TO BATTERIES. WHEN ADDING

WATER TO THE BATTERIES, A NON-METALLIC CONTAINER AND/
OR FUNNEL MUST BE USED.

DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BAT-

TERIES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICA-
TION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

Check the electrolyte level of the batteries often, adding

only distilled water when required. When fully charged,
battery fluid level should be 1/8" below vent tubes. (See
Figure 3-20.). MAF20990

• DO NOT fill to bottom of vent tubes. Figure 3-21. Battery Charger Location
• DO NOT allow fluid level to go below the top of the
plates when charging or operating.

BATTERY FLUID LEVEL OF FULLY

FILLER CAP CHARGED BATTERY
VENT TUBE 1

1/8 "

PLATES

2
Figure 3-20. Battery Fluid Level
MAF25730

1. AC Voltage - Input Plug 2. Charge Indicator LEDs

Figure 3-22. Battery Charger (Delta-Q)

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 SECTION 3 - CHASSIS & SCISSOR ARMS

1. For flooded lead-acid batteries, regularly check

water levels of each battery cell after charging and
add distilled water as required to level specified by
battery manufacturer. Follow the safety instruc-
tions recommended by the battery manufacturer.
2. Make sure charger connections to battery termi-
nals are tight and clean.
3. Do not expose charger to oil or to direct heavy
water spraying when cleaning vehicle.

1
2 3

MAF02550

1. Charger Interlock Cable 3. Power Cable

2. LED Indicator Cable
Figure 3-23. Battery Charger (Green Power)

Battery Charger Maintenance

USE CHARGER ONLY ON BATTERY SYSTEMS WITH AN ALGO-

RITHM SELECTED THAT IS APPROPRIATE TO THE SPECIFIC BAT-
TERY TYPE. OTHER USAGE MAY CAUSE PERSONAL INJURY AND
DAMAGE.

LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN

GAS DURING NORMAL OPERATION. KEEP SPARKS, FLAMES,
AND SMOKING MATERIALS AWAY FROM BATTERIES. PROVIDE
ADEQUATE VENTILATION DURING CHARGING. NEVER CHARGE A
FROZEN BATTERY.

STUDY ALL BATTERY MANUFACTURERS’ SPECIFIC PRECAU-

TIONS SUCH AS RECOMMENDED RATES OF CHARGE AND
REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING.

DANGER
RISK OF ELECTRIC SHOCK. CONNECT CHARGER POWER CORD TO
AN OUTLET THAT HAS BEEN PROPERLY INSTALLED AND
GROUNDED IN ACCORDANCE WITH ALL LOCAL CODES AND ORDI-
NANCES. A GROUNDED OUTLET IS REQUIRED TO REDUCE RISK
OF ELECTRIC SHOCK - DO NOT USE GROUND ADAPTERS OR MOD-
IFY PLUG. DO NOT TOUCH UNINSULATED PORTION OF OUTPUT
CONNECTOR OR UNINSULATED BATTERY TERMINAL. DISCON-
NECT THE AC SUPPLY BEFORE MAKING OR BREAKING THE CON-
NECTIONS TO THE BATTERY WHILE CHARGING. DO NOT OPEN
OR DISASSEMBLE CHARGER. DO NOT OPERATE CHARGER IF THE
AC SUPPLY CORD IS DAMAGED OR IF THE CHARGER HAS
RECEIVED A SHARP BLOW, BEEN DROPPED, OR OTHERWISE
DAMAGED IN ANY WAY - REFER ALL REPAIR WORK TO QUALI-
FIED PERSONNEL. NOT FOR USE BY CHILDREN.

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Table 3-2. Diagnostic Trouble Codes (Delta Q Battery Charger)

DTC Fault Solution

E-0-0-1 Check the battery voltage and cable connections. Check battery size and condition.
Battery high voltage
E-0-2-1 This error will automatically clear once the condition has been corrected.
E-0-0-2 Check the battery voltage and cable connections. Check battery size and condition.
Battery low voltage
E-0-2-2 This error will automatically clear once the condition has been corrected.
Possible causes: Charger output reduced due to high temperatures, poor battery health, very
Charge timeout caused by battery
deeply discharged battery and /or poorly connected battery.
E-0-0-3 pack not reaching required voltage
Possible solutions: Operate at lower ambient temperature. Replace battery pack. Check DC con-
within safe time limit.
nections. This error will automatically clear once the charger is reset by cycling DC or AC.
Possible causes: Check for shorted or damaged cells.
Battery could not meet minimum
E-0-0-4 Possible solutions: Replace battery pack. Check DC connections.
voltage
This error will automatically clear once the charger is reset by cycling DC or AC.
Possible causes include poor battery health, very deeply discharged battery, poorly connected
battery, and / or high parasitic loads on battery while charging.
E-0-0-7 Battery amp hour limit exceeded
Possible solutions: Replace battery pack. Check DC connections. Disconnect parasitic loads. This
error will automatically clear once the charger is reset by cycling DC or AC.
Possible battery temperature sensor error. Check temperature sensor and connections. Reset
E-0-0-8 Battery temperature is out of range
charger. This error will automatically clear once the condition has been corrected.
Battery is connected to the charger incorrectly. Check the battery connections. This error will
E-0-1-2 Reverse polarity error
automatically clear once the condition has been corrected.
E-0-1-6 Software upgrade failure or script operation failure. Ensure the USB flash drive is properly for-
E-0-1-8 USB operation failed
matted and retry inserting the USB flash drive into the charger.
E-0-2-6
Connect charger to an AC source that provides stable AC between 85 - 270 VAC / 45 - 65 Hz. This
E-0-2-3 High AC voltage error (>270 VAC)
error will automatically clear once the condition has been corrected.
The charger has failed to turn on properly. Disconnect AC input and battery for 30 seconds
E-0-2-4 Charger failed to initialize
before retrying.
AC source is unstable. Could be caused by undersized generator and /or severely undersized
input cables. Connect charger to an AC source that provides stable
E-0-2-5 Low AC voltage oscillation error
AC between 85 - 270 VAC / 45-65 Hz. This error will automatically clear once the
condition has been corrected.
Internal charger fault. Remove AC and battery for minimum 30 seconds and retry charger.
F-0-0-1, F-0-0-2, F-0-0-3, F-0-0-4, F-0-0-6
If it fails again, please contact the manufacturer of your vehicle or machine.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Table 3-3. Fault Codes (Green Power)

Flash Code Cause Solution

1) Check battery connection is correct.
1 Connection Issue 2) Check charger connection is correct.
3) Check each battery is good.
1) Check AC input cord is connected between charger and AC outlet.
2 Abnormal AC Power Input (Voltage)
2) Make sure AC plug is tightly secured into AC outlet.
1) Charger shuts down and goes into protection mode due to
charger/environmental temperature is too high for charger to
function properly. Please place the charger into an area with ambi-
3 Charger High Temperature Protection
ent air flow or to a cooler place.
2) Disconnect the charger and wait for 15-20 mins before reco nect-
ing for charging.
1) Charger will reduce or even stop charging when the battery tem-
perature exceeds 50° C. This is to avoid battery overheating.
4 Battery High Temperature Protection
2) Disconnect the charger and wait for 15-20 mins before recon-
necting for charging.
5 Output Current is too high Return to factory for repair.
Check and assure that the correct output battery voltage is
6 Battery Voltage is too high(>30.5 V)
connected.
Check and assure that the correct output battery voltage is
7 Battery Voltage is too low(<18 V)
connected.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Table 3-4. Fault Codes (Eagle Battery Charger)

LED Indications Fault Solution

This indication occurs whenever the charger circuitry cannot detect a bat-
tery. The charger circuitry will not allow charge current to flow under this
30% RED LED
NO BATTERY DETECTED condition. With the AC power supply cord unplugged, check the connection
BLINKING
to the batteries for proper polarity (black wire to negative). Also check for
corrosion free secure connections to the battery.
This indication occurs if the battery voltage has not risen above 1.75 volts
30 & 60% RED LEDS FORMING STAGE TIMEOUT per cell within the first 3 hours of charging. This indicates that a possible
BLINKING SHUTDOWN battery problem exists and that the charge cycle has been terminated at
this point.
This indication occurs if the charger has not completed the charge cycle
30, 60 & 90% RED LEDS within the allowable factory set time period. This indicates that a possible
OVERALL TIMER SHUTDOWN
BLINKING battery problem exists and that the charge cycle has been terminated at
this point.
This indication occurs if the charger circuitry has detected operating
30 & 90% RED LEDS temperatures inside the charger enclosure that are above factory specified
INTERNAL OVERTEMP SHUTDOWN
BLINKING levels. This could indicate that a possible charger problem exists and that
the charge cycle has been terminated.
This indication occurs if the battery voltage does not rise properly during
30% RED & 100% GREEN LEDS
BULK STAGE SHUTDOWN the Bulk Stage. This indicates that a possible battery problem exists and
BLINKING
that the charge cycle has been terminated at this point.
This will be the NORMAL indication when the charger is plugged into A/C
30% RED & 100% GREEN LEDS DELTAVIEW SIGNAL OR NO BATTERY but not connected to a battery pack, allowing the DeltaView signal to be
ALTERNATE BLINKING ON OFF DETECTED retrieved with a DeltaView Reader. This can also be considered the NO BAT-
TERY DETECTED fault code.
NOTE: Disconnecting and reconnecting the AC power supply cord will reset the charger.

31215074 3-35
 SECTION 3 - CHASSIS & SCISSOR ARMS

Excessive Battery Watering Requirements or Strong 2. To change the algorithm, touch the connector to
Sulphur (Rotten Egg) Smell the battery’s positive terminal for 3 seconds during
the 11 second display period and then remove.
These symptoms indicate over-charging or high battery The Algorithm # will advance after 3 seconds.
temperature. These symptoms are unlikely to be caused Repeat this procedure until the desired Algorithm
by too high a charge current since the maximum charge # is displayed. A 30 second time-out is extended
current of the charger will be small compared to even a for every increment. Incrementing beyond the last
moderately sized battery pack. The most likely cause for Algorithm will recycle back to the first Algorithm.
this problem is incorrect charge algorithm setting and/ When the desired Algorithm is displayed, touch
or high ambient temperatures. the charger connector to the battery positive ter-
1. Confirm that the battery pack is not too small - minal until the output relay makes a clicking noise
usually > 50Ah. (approx. 10 seconds). The algorithm is now in the
2. Confirm that the nominal battery voltage matches permanent memory.
the charger output voltage. 3. Remove the AC power from the charger and
3. Confirm the correct battery charge algorithm. If reconnect the charger’s positive connector to the
the battery pack is new, the algorithm will need to battery. It is recommended to check a newly
be changed if the pack is not the same as the old changed algorithm by repeating the above steps 1
one. for instructions on how to determine and and 3.
change the battery charge algorithm see the fol-
lowing sub-section. Table 3-5. Battery Algorithms
4. If the output voltage of the charger seems exces-
sive, return the charger for service. Contact JLG to Algorithm # Battery Type
get the expected battery voltage settings for the 43 Harris Battery Discover EVGC6A-A (AGM)
charger in question. Be sure to have the charger’s
serial number and charge algorithm setting avail- 35 JLG PN 0400242
able when calling. 23 Douglas Flooded (JLG default)
Checking/Changing the Battery Charge Algorithm GES Battery A1055
Trojan T105
The charger is pre-loaded with programming algo- East Penn GC-110-WNL
rithms for the specific batteries detailed in Table 3-5, Trojan T105 PLUS
Battery Algorithms. Contact JLG if your specific battery Champion CHGC2 GC2
model is not listed. US BATT EV-145-WNL
Each time AC power is applied with the battery pack not US BATT 2200 XC
connected, the charger enters an algorithm select/dis-
play mode for approximately 11 seconds. During this 8 Concorde 10xAh AGM
time, the current Algorithm # is indicated on the Yellow 7 J305 DV/DT CP
Charging LED. A single digit Algorithm # is indicated by 6 DEKA 8G31 Gel
the number of blinks separated by a pause. A two digit
Algorithm # is indicated by the number of blinks for the 5 Trojan 30/31XHS
first digit followed by a short pause, then the number of 4 US Battery USB2200
blinks for the second digit followed by a longer pause.
3 T105 DV/DT CP
To check/change the charging algorithm: 2 Trojan T105 tapped
1. Disconnect the charger positive connector from 1 Trojan T105
the battery pack. Apply AC power and after the
LED test, the Algorithm # will display for 11 sec-
onds.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

3.11 BATTERY CHARGER/INVERTER (OPTION) Battery Charger/Inverter Troubleshooting

The Battery Charger/Inverter is located on the top of the The Fault LED Flash Codes are the same as the Battery
chassis at the rear of the machine. Raise and secure scis- Charger (see Battery Charger Troubleshooting on pages
sor arms with arm prop to gain access to the charger. 3-29 and 3-30).
For further specification and troubleshooting informa-
tion refer to the manufacturers’ Charger/Inverter
Owner’s Guide shipped with the machine. Publication -
RM1024-JLG - Part # 3128406.
Use the information below to supplement the informa-
tion in the Inverter/Charger manual. First, go through
the troubleshooting in the Owner’s Guide (JLG part
number 3128406), then use the procedures below. For
control of the Inverter/Charger there is an 8 position
connector on a cable entering the case of the Inverter/
Charger. Looking at the pins of the connector, terminals
are numbered clockwise starting with number 1 nearest
the notch. Terminal 8 is in the center.
No charge voltage:
1. Disconnect control cable from Inverter/charger.
2. Turn on machine.
3. Inverter/charger control cable 8 position connec-
tor socket 1 should have Vbatt present. If it is not,
check charger interlock connector, 2 position,
socket 1. If voltage is present there replace the
Inverter/Charger data interface harness. If Vbatt is
Figure 3-24. Battery Charger/Inverter Location not present at the 2 position connector socket 1,
check the circuit through the chassis harness back
to Ground Module terminal J1-19.
Loads will not start when there is no external AC/
5
6 Inverter will not produce AC power:
4
1. Check that Inverter/Charger switch is in ON posi-
tion.
2. Disconnect control cable from the Inverter/Char-
1 ger.
2
3 3. Turn on machine.
4. Inverter/Charger control cable socket 2 should
have Vbatt present when the switch is ON. If not
check that there is Vbatt on the switch Yellow/Red
wire. Vbatt signal originates from Ground module
pin J1-19 then goes to harness Interlock connector
terminal 1 (Yellow/Red wire), then to switch.
LED(s) suspected to be bad:
1. AC Output Connector 4. External DC Fuse Location
2. AC Input Connector 5. DC (+) Connection 1. Disconnect Inverter/Charger control cable from
3. Remote On/Off Switch Cable 6. DC (-) Connection the charger (8 position connector) and the 6 posi-
tion connector at the chassis harness. There
Figure 3-25. Battery Charger/Inverter should be continuity between the following:
a. 8 pos. terminal 3 to 6 pos. terminal 3
b. 8 pos. terminal 4 to 6 pos. terminal 5
c. 8 pos. terminal 5 to 6 pos. terminal 4
d. 8 pos. terminal 6 to 6 pos. terminal 6

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 SECTION 3 - CHASSIS & SCISSOR ARMS

2. Disconnect Inverter/Charger control cable at the 6 Ground Module powered while key is off or similar
position connector and the chassis harness at the behavior:
4 position connector at the Ground Box. There
This condition can be caused by various ground module
should be continuity between the following:
outputs getting shorted to battery. If not done already,
a. 6 pos. terminal 3 to 4 pos. terminal 1 cycle power and check for fault codes. If no fault codes,
b. 6 pos. terminal 4 to 4 pos. terminal 3 perform the following:
c. 6 pos. terminal 5 to 4 pos. terminal 2 1. Disconnect the Inverter/Charger control cable at
d. 6 pos. terminal 6 to 4 pos. terminal 4 the 8 position connector and the 2 position Inter-
3. If wiring is found to be good, the LED printed cir- lock connector.
cuit card is likely to be bad. 2. Set digital multimeter to diode check or continuity
Interlock Cable suspected to be bad or vehicle thinks check to check diode in Inverter/Charger control
charging is in progress, but it is not: harness. If the meter does not have these features
a low range Ohm scale (20 Ohms for example) will
1. Disconnect Interlock (2 position) connector on the work.
Inverter/Charger control cable. 3. Place red lead on 8 position connector pin 1. Place
2. Turn on machine. black lead on Interlock connector pin 1.
3. There should be Vbatt present on the Interlock 4. Meter should read an open. Swap leads. Meter
connector socket 1. should read a short. If either condition is not good,
4. Turn off machine. replace Inverter/Charger control cable.
5. Disconnect Inverter/Charger control cable at the
charger.
6. Inverter/Charger connector (8 position) pin 6
should have continuity to Interlock connector pin
2 and then to ground module socket J1-29.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

3.12 LIMIT SWITCH LOCATIONS

1. Pothole Switch (Typical on opposite side of machine)

2. Rotary Angle Switch

Figure 3-26. Limit Switch Locations

31215074 3-39
 SECTION 3 - CHASSIS & SCISSOR ARMS

Pothole Switch Replacement

POTHOLE
SWITCH

LINK

SEE DETAIL A

DETAIL A

For 1930ES, 2032ES and 2632ES

POTHOLE
SWITCH

LINK

SEE DETAIL B

DETAIL B
For 2646ES and 3264ES MAF21000

Figure 3-27. Pothole Switch Adjustment

1. With the machine in the stowed position and the 6. Raise and lower the machine from the ground con-
battery door open, remove the old pothole switch. trol several times to ensure that the switch is func-
2. Mount the new limit switch and harness to crank tioning properly.
with the washer placed behind the switch. NOTE: From the platform, raise and lower the machine and
3. Adjust the switch by inserting an 0.25 in. shim check that the switch is operating properly by cutting
between the link and the switch plunger. back to elevated speed when the pothole is deployed.
4. Push the switch to fully depress the plunger and Drive will be cutout if pothole is not set.
tighten the switch screws.
5. Repeat this procedure on the opposite side.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

Rotary Angle Sensor Replacement 3.13 GROUND CONTROL STATION

Removal: NOTE: Anytime the ground control box is removed, the tilt
sensor must be re-calibrated. Refer to Section 5.3, Tilt
1. Lower platform to the stowed position. Sensor Calibration to re calibrate the tilt.
2. Disable the machine and disconnect the batteries.
3. Remove the screws securing the sensor cover to Box Disassembly
the frame and remove the sensor cover.
4. Disconnect the wiring harness from old/existing
rotary angle sensor. Disconnect the sensor from
the arm pin and remove the sensor.
Installation:
1. Connect the wiring harness to the new rotary
angle sensor.
2. Position and connect rotary angle sensor to the
arm pin as shown below.

1. Disconnect the batteries.

2. Remove the three bolts at the bottom of the
ground control station.

3. Rotate the sensor as described in the image above.

NOTE: The sensor is spring loaded. DO NOT rotate past its
internal stops.
4. Install the rotary angle sensor cover and secure to
the frame with the two screws.
5. Reconnect the batteries.

3. Remove the four bolts where the control cable

enters into the control box.
4. Remove plug and place control box face down on
a suitable work bench.

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 SECTION 3 - CHASSIS & SCISSOR ARMS

.
Tilt Sensor Replacement

5. Remove the six bolts at the back of the ground

control and separate.
1 2
1. Ground Control Station
2. Tilt Sensor (JLG PN 4000021 or
1001114936)

Figure 3-28. Tilt Sensor Location

Tilt Sensor Removal:

1. Disconnect the batteries.

2. Open the Ground Control Station to gain access to
the Tilt Sensor Assembly. (refer to prior mentioned
procedures)
3. Remove the four Screws (3), to remove the Tilt Sen-
sor (1) and Sensor Mount (2) from the Ground Con-
trol Box.
4. The Tilt Sensor (1) can be removed from the Sensor
Mount (2) by removing the three Screws (4).
NOTE: Follow the above procedures in reverse order when
installing the tilt sensor assembly. After installing, be
sure to calibrate the tilt sensor (refer to Section 5.3,
Tilt Sensor Calibration).

3-42 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

3.14 SCISSOR ARMS AND PLATFORM POSITIONING

AND SUPPORT
4 1 CAUTION
PLATFORM IS HEAVY AND PRESENTS A CRUSHING HAZARD.
3 TAKE GREAT CARE WHEN REMOVING PLATFORM OR SCISSOR
ARM ASSEMBLY

The arm stack can be supported by using an overhead

2 crane,(See Figure 3-30.). If an overhead crane is not
available the stack may also be lifted by using a
forktruck using the following instructions:
1. With the forks on the forktruck slid close together,
enter from the front of the machine and place the
forks on the cross tube of the second arm weld-
ment below the platform.
2. Slowly lift the arm stack with the forktruck while
the manual descent valve is being engaged (this
allows the oil to drain back into the tank).
3. Place machine on safety prop and leave the
forktruck in place.
4. At this point the lift cylinder removal may begin.
(Refer to Section 4.7, Lift Cylinder Removal)
If removal of the platform becomes necessary use the
1. Tilt Sensor above procedure to stabilize the platform for pin and
2. Sensor Mount platform removal.
3. Screw, 3.5 x 0.6 x 16 LG
4. Screw, 3.5 x 0.6 x 10 LG

Figure 3-29. Tilt Sensor Removal

Table 3-6. Tilt Sensor Harness

Wire Color Function Connector Pin

Red VCC 1
White CANH 2
Green CANL 3
Black Ground 4

31215074 3-43
 SECTION 3 - CHASSIS & SCISSOR ARMS

3.15 PLATFORM REMOVAL 3.16 SCISSOR ARMS REMOVAL

1. Support the platform using an overhead crane 1. Remove platform (refer to Section 3.15, Platform
with straps capable of lifting at least 439 lb Removal).
(199 kg) (See Figure 3-30.). Refer to Section 3.14, 2. Disconnect all wiring and cables attached to scis-
Scissor Arms and Platform Positioning and Sup- sor arm assembly.
port. 3. Remove lift cylinder (refer to Section 4.7, Lift Cylin-
2. Disconnect the battery plug at the chassis. Discon- der Removal).
nect platform cable and foot switch cable, if appli- 4. The scissor arms can be removed as a complete
cable, from railing. Route the cables out through unit or individually.
the hole at the rear of the platform to free platform
Removing scissor arm assembly as a complete unit:
of any constraints. If platform is equipped with an
outlet plug, disconnect and route cable out of 1. Remove the pin attaching the bottom scissor arms
platform. to the rear of the frame by removing the bolt.
3. Remove the bolts attaching the pins and slide 2. Place two straps around each end of the the entire
blocks at each corner to the arm stack. Carefully scissor arm assembly. Using an overhead crane,
remove the four pins attaching the platform to the slowly and carefully move the arm stack forwards
arm stack. so that slide blocks at front of machine slide out
4. Lift the platform from the armstack and set aside. the front of the slide channel on the frame.
NOTE: When attaching platform back onto scissor arm NOTE: Overhead crane and straps must be capable of lifting
at least 1953 lb (886 kg).
assembly, follow removal procedures in reverse
order. 3. Once slide blocks are clear of machine, the scissor
stack can be moved to a more desirable location
NOTICE for further arm disassembly.
Removing scissor arms individually:
FOR MACHINES EQUIPPED WITH LOAD SENSING SYSTEM (LSS),
ENSURE ARROWS ON THE LSS PIN ARE POINTING DOWN 1. Start with the top arms (closest to platform).
BEFORE INSERTING BOLTS INTO PIN. NOT APPLICABLE FOR 2. Secure each arm section being removed using an
MACHINES WITHOUT LSS. overhead crane with suitable lifting straps.
3. Remove the bolts securing the connecting pins in
place.
4. Remove the pins from the arms.
5. Remove the arm section from the machine using
the overhead crane.
6. Repeat previous steps for remaining arm sections.
NOTE: When attaching scissor arm assembly back onto
frame, follow removal procedures in reverse order.
Self locking fasteners, such as nylon insert and thread
deforming locknuts, are not intended to be reinstalled
after removal. Always use new replacement hardware
when installing locking fasteners.

3-44 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-30. Arms and Platform Positioning and Support

31215074 3-45
 SECTION 3 - CHASSIS & SCISSOR ARMS

11
10

1
9

12

5
4
8 3
7
6 1001131004-D
4 MAF21010D

1. Arm Assembly 5. Arm Pivot Pin 9. Cable

2. Capscrew 6. Angle Sensor Switch 10. Lock Nut
3. Lock Nut 7. Agle Sensor Mount 11. Spring
4. Lower Side Pad 8. Capscrew 12. Tape

Figure 3-31. Scissors Arms Assembly - 1930ES

3-46 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

9
6
3
1

LIFT CYLINDER VIEW

SHOWN HERE FOR CLARITY

5
8
2

4
11
7
10
1001131005-D
MAF21020D

1. Arm Assembly 5. Lock Nut 9. Spring

2. Capscrew 6. Lock Nut 10. Capscrew
3. Cable 7. Lower Side Pad 11. Angle Sensor Switch
4. Angle Sensor Mount 8. Arm Pivot Pin
Figure 3-32. Scissors Arms Assembly - 2032ES

31215074 3-47
 SECTION 3 - CHASSIS & SCISSOR ARMS

11

8
5
2

LIFT CYLINDER VIEW

SHOWN HERE FOR CLARITY

4
7
3 1 6

10
9 6
1001190904-A
MAF21030A

1. Capscrew 5. Lock Nut 9. Capscrew

2. Cable 6. Lower Side Pad 10. Angle Sensor Switch
3. Angle Sensor Mount 7. Arm Pivot Pin 11. Arm Assembly
4. Lock Nut 8. Spring
Figure 3-33. Scissors Arms Assembly - 2632ES

3-48 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

11

10

13
10
2 5 8

1 12 3
9

4
7
LIFT CYLINDER VIEW
SHOWN HERE FOR CLARITY

1001191063-B
1001191064-B
MAF21040B

1. Capscrew 6. Lower Side Pad 11. Tape

2. Cable 7. Arm Pivot Pin 12. Angle Sensor Switch
3. Angle Sensor Mount 8. Spring 13. Arm Assembly
4. Lock Nut 9. Capscrew
5. Lock Nut 10. Tape
Figure 3-34. Scissors Arms Assembly - 2646ES and 3246ES

31215074 3-49
 SECTION 3 - CHASSIS & SCISSOR ARMS

3.17 PLATFORM CONTROL STATION 4. Loosen and remove the four bolts that hold the
bottom of the control box.
Printed Circuit Board Replacement 5. Disconnect the plug from the printed circuit
board.
1. Disconnect the platform control box and remove
6. Remove the bolts attaching the printed circuit
from the machine.
board to the control box.
2. Place the platform control box on a suitable work
7. Replace board and reassemble control box.
bench.
3. Loosen and remove the long through bolts that
hold the two side control housings together.
NOTE: You may have to only loosen the two power bolts
and remove the two closest the top in order to get to
the printed circuit board located in the top of the
control box where the drive/lift select switch is
located.

3-50 31215074
 SECTION 3 - CHASSIS & SCISSOR ARMS

Joystick Controller

Figure 3-35. Joystick

Table 3-7. Joystick Specifications Table 3-8. Connector Chart

Input Voltage +5 (±0.1) VDC CONNECTOR PINOUT

Current Consumption 10 mA @ 12 VDC Term Color Function
Output: Handle Centered 2.5 (±0.1) VDC 1 RED HANDLE COM
Output: Full Positive (Reverse) Deflection 4 (±0.1) VDC 2 VIOLET TRIGGER N.O.
3 -- SPARE
Output: Full Negative (Forward) Deflection 1 (±0.1) VDC
4 YELLOW ROCKER RT
5 GREEN ROCKER LT
6 -- SPARE
7 WHITE/RED +5VDC
8 WHITE/BLACK GROUND
9 BROWN SIG OUTPUT

31215074 3-51
 SECTION 3 - CHASSIS & SCISSOR ARMS

3-52 31215074
 SECTION 4 - HYDRAULICS

SECTION 4. HYDRAULICS
4.1 CYLINDERS - THEORY OF OPERATION Relief Valves
Cylinders are of the double acting type. The Lift and Main relief valves are installed at various points within
Steer systems incorporate double acting cylinders. A the hydraulic system to protect associated systems and
double acting cylinder is one that requires oil flow to components against excessive pressure. Excessive pres-
operate the cylinder rod in both directions. Directing oil sure can be developed when a cylinder reaches its limit
(by actuating the corresponding control valve to the of travel and the flow of pressurized fluid continues
piston side of the cylinder) forces the piston to travel from the system control. The relief valve provides an
toward the rod end of the barrel, extending the cylinder alternate path for the continuing flow from the pump,
rod (piston attached to rod). When the oil flow is thus preventing rupture of the cylinder, hydraulic line or
stopped, movement of the rod will stop. By directing oil fitting. Complete failure of the system pump is also
to the rod side of the cylinder, the piston will be forced avoided by relieving circuit pressure. The relief valve is
in the opposite direction and the cylinder rod will installed in the circuit between the pump outlet (pres-
retract. sure line) and the cylinder of the circuit, generally as an
integral part of the system valve bank. Relief pressures
NOTE: The lift cylinder is a single acting cylinder which takes are set slightly higher than the load requirement, with
hydraulic pressure to extend and gravity to retract. the valve diverting excess pump delivery back to the
A holding valve is used in the Lift circuit to prevent reservoir when operating pressure of the component is
retraction of the cylinder rod should a hydraulic line reached.
rupture or a leak develop between the cylinder and its
related control valve. Crossover Relief Valves
4.2 VALVES - THEORY OF OPERATION Crossover relief valves are used in circuits where the
actuator requires an operating pressure lower than that
supplied to the system. When the circuit is activated and
Solenoid Control Valves (Bang-Bang) the required pressure at the actuator is developed, the
Control valves used are four-way, three-position sole- crossover relief diverts excess pump flow to the reser-
noid valves of the sliding spool design. When a circuit is voir. Individual, integral relief’s are provided for each
activated and the control valve solenoid energizes, the side of the circuit.
spool is shifted and the corresponding work port opens
to permit oil flow to the component in the selected cir- Proportional Valve
cuit, with the opposite work port opening to reservoir.
Flow is proportional to the amount of voltage supplied
Once the circuit is deactivated (control returned to neu-
to the valve coil. Voltage is gained by the machine con-
tral), the valve spool returns to neutral (center) and oil
troller and determined by the position of the joystick.
flow is then directed through the valve body and
returns to reservoir. A typical control valve consists of
the valve body, sliding spool, and two solenoid assem- Manual Descent Valve
blies. The spool is machine fitted in the bore of the valve
The manual descent valve is located on top of the hold-
body. Lands on the spool divide the bore into various
ing valve on the lift cylinder. The holding valve is a nor-
chambers, which, when the spool is shifted, align with
mally closed solenoid valve, and holds the platform in
corresponding ports in the valve body open to common
place when raised. When activated, the valve opens to
flow. At the same time other ports would be blocked to
permit lift down. The holding valve is connected to the
flow. The spool is spring-loaded to center position,
manual descent valve, which is connected to a cable
therefore when the control is released, the spool auto-
which, when pulled, manually opens the lift down port
matically returns to neutral, prohibiting any flow
of the valve and allows the platform to be lowered in the
through the circuit.
event hydraulic power is lost.

31215074 4-1
 SECTION 4 - HYDRAULICS

4.3 CYLINDER CHECKING PROCEDURE 4.4 LIFT PRESSURE SETTING PROCEDURE

NOTE: Cylinder check must be performed anytime a system
component is replaced or when improper system
operation is suspected.

Cylinders Without Counterbalance Valves and

Steer Cylinder
1. Using all applicable safety precautions, activate
pump motor and fully extend cylinder to be
checked.
2. Carefully disconnect hydraulic hoses from retract
port of cylinder. There will be some initial weeping
of hydraulic fluid which can be caught in a suitable
container. After the initial discharge, there should
be no further drainage from the retract port.
3. Activate pump motor and extend cylinder.
4. If cylinder retract port leakage is less than 6-8
drops per minute, carefully reconnect hose to port
and retract cylinder. If leakage continues at a rate
of 6-8 drops per minute or more, cylinder repair
must be made.
5. With cylinder fully retracted, shut down machine
power and carefully disconnect hydraulic hose
from cylinder extend port.
6. Activate pump motor and retract cylinder. Check
extend port for leakage.
7. If extend port leakage is less than 6-8 drops per 1. Large Nut
minute, carefully reconnect hose to extend port, 2. Pressure Setting Screw
than activate cylinder through one complete cycle
and check for leaks. If leakage continues at a rate 3. P port
of 6-8 drops per minute or more, cylinder repairs
must be made. Figure 4-1. Lift Pressure Setting

1. Place 120% of the rated load of the machine on

the platform.
2. Increase lift pressure to raise the platform and set
the safety prop.
3. Locate the Large Nut (1) on the underside of the
valve block.
4. Using a 7/8 in. wrench, remove the large nut (1).
This will expose the Pressure Setting Screw (2).
5. Remove plug from P port (3) and install a pressure
gauge.
6. Raise the platform and take a pressure reading.
7. Adjust the Pressure Setting Screw to reach the
proper lift pressure per model as listed in Table 4-
1.

4-2 31215074
 SECTION 4 - HYDRAULICS

Table 4-1. Pressure Settings 4.5 HYDRAULIC OIL FILL

Lift Relief NOTE: The hydraulic oil level should be checked every 6
Model Steer Relief months. Always check the oil level any time any
USA Built China Built maintenance is performed that would effect the
hydraulic oil level.
1800 psi ± 50 psi 1900 psi ± 50 psi 1500 psi
1930ES Oil Check Procedure
(124 bar ± 3.4 bar) (131 bar ± 3.4 bar) (103 bar)

1800 psi ± 50 psi 1900 psi ± 50 psi 1500 psi 1. With the scissor lift on a flat and level surface and
2032ES
(124 bar ± 3.4 bar) (131 bar ± 3.4 bar) (103 bar) the platform empty, elevate machine and swing
safety prop out of it’s stowed position.
1950 psi +/- 50 psi 1900 psi ± 50 psi 1500 psi
2632ES 2. Continue to elevate the platform until the fill plug,
(134 bar ± 3.4 bar) (131 bar ± 3.4 bar) (103 bar)
located on the right side of the tank attached to
2000 psi +/- 50 psi 1900 psi ± 50 psi 1500 psi the lift cylinder, is fully accessible.
2646ES
(138 bar ± 3.4 bar) (131 bar ± 3.4 bar) (103 bar)

2000 psi +/- 50 psi 1900 psi ± 50 psi 1500 psi CAUTION
3246ES ENSURE THE SCISSOR ARMS ARE PROPERLY SUPPORTED.
(138 bar ± 3.4 bar) (131 bar ± 3.4 bar) (103 bar)

NOTE: Check your nameplate at the left rear of the machine NOTE: The 2632ES/2646ES/ 3246ES platforms will have to
for country of origin. USA built machines, serial num- be raised higher than the 1930ES and 2032ES in
ber prefix starts with a 02 (02XXXXXXXX), China built order to access the oil plug.
machines, serial number prefix starts with an B2
(B2XXXXXXXX).

8. Remove pressure gauge and replace the plug into

the P port.
9. Replace the bronze washer with a new bronze
washer and large nut over the pressure setting
screw. Do not use old bronze washer. Using the old
bronze washer will cause leakage.
10. Torque the large nut to 160 in. lb (16 Nm).
Alternate Lift Pressure Setting Procedure:
1. Increase lift pressure to raise the platform and set
the safety prop.
2. Remove plug from port P (3) and install a pressure
gauge. 3. Wipe all dirt and debris from the filler plug area.
3. Remove the solenoid from the lift valve. 4. Slowly remove the fill plug venting any pressure
4. Set the pressure actuating lift function from the that may be built up in the reservoir.
ground or platform. 5. To check the oil level, lower platform so it rests on
5. Remove the pressure gauge from port P (3) and the safety porp.
replace plug.
6. Replace the solenoid on the lift valve. CAUTION
THERE MAY BE UP TO 10 PSI OF PRESSURE IN THE TANK.

6. With the plug removed, the oil level should be

completely full, at the top of the fill port with scis-
sor arms resting on the safety prop. from the fill
port.
7. If additional oil is required, add proper grade of oil
by using a funnel with a flexible spout or a plastic
squeeze bottle. Fill until oil weeps out of opening.

31215074 4-3
 SECTION 4 - HYDRAULICS

NOTE: Care should be taken not to introduce any impurities 4. Apply a layer of grease along the inside and top of
(dirt, water etc.) while plug is removed. the upper slide channel (2) on both sides of the
machine.
8. Replace plug and torque to 40 ft. lbs. (56 Nm).
9. Any time a hydraulic component is removed or
replaced, cycle the scissor arms several times and
refer to steps 3 and 4 to recheck oil level.

Slide Block Lubrication

Lube - White Lithium Grease (GREDAG 741)
Interval - Every 6 months
1. With the platform empty, elevate machine and
swing safety prop out of it’s stowed position.

CAUTION
ENSURE THE SCISSOR ARMS ARE PROPERLY SUPPORTED.

2. Locate the Lower and Upper Slide Pads and wipe/

pressure wash all dirt and debris from the slide Upper Slide Pad Channel
channel area (1, 2).
3. Apply a layer of grease along the inside and bot-
tom of the lower slide channel (1) on both sides of
the machine.

Upper Slide Pad Channel

4-4 31215074
 SECTION 4 - HYDRAULICS

4.6 LIFT CYLINDER REMOVAL

NOTE: If there is a pump failure, a crane or a forktruck can
be used to raise the platform. Refer to Figure 3-47.,
Arms and Platform Positioning and Support.
Self locking fasteners, such as nylon insert and thread
deforming locknuts, are not intended to be reinstalled
after removal. Always use new replacement hardware
when installing locking fasteners.
1. Raise the platform and place on the safety prop. It
may be necessary to use an overhead crane or fork
truck to secure the platform and scissor arms
before lift cylinder removal begins. (See Figure 3-
47.)
2. Cut any wire ties that attach any cables or hoses to
the lift cylinder.

NOTICE
PULL THE BATTERY DISCONNECT BEFORE REMOVING ANY COM-
PONENTS FROM THE LIFT CYLINDER ASSEMBLY.
3. Remove the valves connectors, the two battery
cables and the manual decent cable.
NOTE: To avoid having to readjust the manual descent,
remove the large nut located behind the manual
descent bracket as shown. (See Figure 4-2.)
4. Ensuring that the platform and scissor arms are
properly secure, remove the top lift cylinder pin
and rest the top of the cylinder on the arm cross
tube directly below the cylinder.
5. Remove the bolt form the lower cylinder pin and
have someone assist you in lifting the cylinder
from the scissor arms.
6. Set the cylinder with pump and motor assembly
intact on a clean workbench.
7. Remove the 4 bolts that attach the pump/motor
assembly to the lift cylinder.
8. Remove the bolt from the bracket that attaches
the hydraulic reservoir to the lift cylinder.
9. Separate the cylinder from the pump/motor
assembly.

31215074 4-5
 SECTION 4 - HYDRAULICS

1. Battery Cables 3. Manual Descent 5. Top Cylinder Bolt (Torque 41 ft. lbs.)
2. Valves 4. Steer Hoses 6. Bottom Cylinder Bolt

Figure 4-2. LIft Cylinder Removal

4-6 31215074
 SECTION 4 - HYDRAULICS

4.7 CYLINDER REPAIR 7. Being careful not to mark the surface of the rod,
use a punch or wooden dowel and hammer to
NOTE: The following are general procedures that apply to drive the rod guide about one inch down into the
all of the cylinders on this machine. Procedures that cylinder bore. Using a screw driver, carefully push
apply to a specific cylinder will be so noted. one end of the round retaining ring back towards
the inside of the cylinder and then slip the screw-
Disassembly driver tip under that end. Pull the ring out of the
groove toward the wall mouth. Once one end of
the retaining ring is free from the groove, the
NOTICE remainder can be easily pried free using ones fin-
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A gers or pliers.
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 8. Attach a suitable pulling device to the cylinder rod
port block end or cylinder rod end, as applicable.
1. Connect a suitable auxiliary hydraulic power
source to the port block fitting in the manifold NOTICE
located on the cylinder.
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-
INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. CYLINDER BARREL SURFACES.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.
9. With the barrel clamped securely, apply pressure
2. Operate the hydraulic power source and extend to the rod pulling device and carefully withdraw
the cylinder. Shut down and disconnect the power the complete rod assembly from the cylinder bar-
source. Adequately support the cylinder rod, if rel.
applicable.
3. If applicable, remove the cartridge-type holding
valve and fittings from the cylinder port block. Dis-
card o-rings.
4. Place the cylinder barrel into a suitable holding fix-
ture.

Figure 4-4. Cylinder Rod Support

10. Using suitable protection, clamp the cylinder rod

in a vise or similar holding fixture as close to the
piston as possible.
NOTE: For steer cylinder piston removal, see Steer Cylinder
Piston Removal on page 4-8 following.
Figure 4-3. Cylinder Barrel Support
11. Loosen and remove the capscrews, if applicable,
which attach the tapered bushing to the piston.
5. Mark cylinder head and barrel with a center punch
for easy realignment. Loosen the cylinder head 12. Insert the capscrews in the threaded holes in the
setscrew. outer piece of the tapered bushing. Progressively
tighten the capscrews until the bushing is loose on
NOTE: Steps 6 and 7 apply only to the steer cylinder. the piston.
6. Using a spanner wrench, loosen the spanner nut 13. Remove the bushing from the piston.
retainer, and remove spanner nut from cylinder 14. Screw the piston CCW, by hand, and remove the
barrel. piston from cylinder rod.

31215074 4-7
 SECTION 4 - HYDRAULICS

15. Remove and discard the piston o-rings, seal rings, 9. Inspect cylinder head inside diameter for scoring
and backup rings. or other damage and for ovality and tapering.
16. If applicable, remove the piston spacer from the Replace as necessary.
rod. 10. Inspect threaded portion of head for damage.
17. Remove the rod from the holding fixture. Remove Dress threads as necessary.
the cylinder head gland and retainer plate, if appli-
cable. Discard the o-rings, backup rings, rod seals, 11. Inspect seal and o-ring grooves in head for burrs
and wiper seals. and sharp edges. Dress applicable surfaces as nec-
essary.
Steer Cylinder Piston Removal 12. Inspect cylinder head outside diameter for scoring
1. Using the spanner holes, rotate the piston until the or other damage and ovality and tapering. Replace
end of the retaining ring can be seen through the as necessary.
cross-drilled retaining ring hole.
13. If applicable, inspect rod and barrel bearings for
2. Insert a flathead screwdriver (or similar tool) into signs of correct excessive wear or damage. Replace
the cross-drilled retaining ring hole. as necessary.
3. Using the screwdriver, guide the retaining ring
a. Thoroughly clean hole, (steel bushing) of burrs,
into the cross-drilled retaining ring hole while
turning the piston. dirt etc. to facilitate bearing installation.
4. Continue turning the piston approximately one (1) b. Inspect steel bushing for wear or other dam-
full turn until the start of the retaining ring is again age. If steel bushing is worn or damaged, rod/
aligned with the cross-drilled retaining ring hole. barrel must be replaced.
5. Lift up on the retaining ring so that the hook on c. Lubricate inside of steel bushing with WD40
the start of the retaining ring releases from the prior to bearing installation.
hole in the rod.
6. Pull the retraining ring all the way out of the cross- d. Using an arbor of the correct size, carefully
drilled retraining ring hole. press the bearing into steel bushing.
7. Slide the piston over the rod in the direction of the NOTE: Install pin into the Gar-Max bearing dry. Lubrication
spanner holes to remove. is not required with nickel plated pins and bearings.
Cleaning and Inspection
STEEL
1. Clean all parts thoroughly in an approved cleaning GAR-MAX
BUSHING
solvent. BUSHING
2. Inspect the cylinder rod for scoring, tapering, oval-
ity, or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace rod if neces-
sary.
3. Inspect threaded portion of rod for excessive dam- ARBOR
age. Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for Figure 4-5. Gar-Max Bearing Installation
scoring or other damage. Check inside diameter
for tapering or ovality. Replace if necessary. 14. Inspect travel limiting collar or spacer for burrs and
5. Inspect threaded portion of barrel for damage. sharp edges. If necessary, dress inside diameter
Dress threads as necessary. surface with Scotch Brite or equivalent.
6. Inspect piston surface for damage and scoring and 15. If applicable, inspect port block fittings and hold-
for distortion. Dress piston surface or replace pis- ing valve. Replace as necessary.
ton as necessary.
16. Inspect the oil ports for blockage or the presence
7. Inspect threaded portion of piston for damage.
Dress threads as necessary. of dirt or other foreign material. Repair as neces-
sary.
8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as nec- 17. If applicable, inspect piston rings for cracks or
essary. other damage. Replace as necessary.

4-8 31215074
 SECTION 4 - HYDRAULICS

Assembly
NOTE: Prior to cylinder assembly, ensure that the proper cyl-
inder seal kit is used. See your JLG Parts Manual
(3121167).
Apply a light film of hydraulic oil to all components prior
to assembly.
1. A special tool is used to install a new rod seal into
the applicable cylinder head gland groove.

Figure 4-8. Wiper Seal Installation

3. Place a new “O-ring and backup seal in the appli-

cable outside diameter groove of the cylinder
head.

Figure 4-6. Rod Seal Installation

NOTICE
WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS
ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLA-
TION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
INSTALLATION COULD RESULT IN C YLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION. Figure 4-9. Installation of Head Seal Kit

2. Use a soft mallet to tap a new wiper seal into the 4. Install washer ring onto rod, carefully install the
applicable cylinder head gland groove. Install a head gland on the rod, ensuring that the wiper
new wear ring into the applicable cylinder head and rod seals are not damaged or dislodged. Push
glandgroove. the head along the rod to the rod end, as applica-
ble.
5. Carefully slide the piston spacer on the rod.

NOTE: Upper telescope cylinder piston has an o-ring

installed inside the spacer.

6. If applicable, correctly place new o-ring in the

inner piston diameter groove. (The backup ring
side facing the O-ring is grooved.)
7. If applicable, correctly place new seals and guide
Figure 4-7. Poly-Pak Piston Seal Installation lock rings in the outer piston diameter groove. (A
tube, with I.D. slightly larger than the O.D. of the
piston is recommended to install the solid seal.)

NOTE: The backup rings for the solid seal have a radius on
one side. This side faces the solid seal.(See magnified
insert in Figure 4-9. The split of seals and backup
rings are to be positioned so as not to be in align-
ment with each other.

31215074 4-9
 SECTION 4 - HYDRAULICS

14. Retorque the capscrews evenly and progressively

in rotation to the specified torque value.
15. Remove the cylinder rod from the holding fixture.
16. Place new guide locks and seals in the applicable
outside diameter grooves of the cylinder piston.
(See Figure 4-10.)
PISTON
17. Position the cylinder barrel in a suitable holding
fixture.

BACKUP
NOTICE
SPLIT SEAL
RINGS
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYL-
INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.
18. With the barrel clamped securely, and while ade-
quately supporting the rod, insert the piston end
SPLIT
BACKUP
into the barrel cylinder. Ensure that the piston
RING loading o-ring and seal ring are not damaged or
O-RING
dislodged.
19. Continue pushing the rod into the barrel until the
cylinder head gland can be inserted into the barrel
T - RING
cylinder.
SEAL
SPLIT BACKUP RING
20. Secure the cylinder head gland using the washer
ring and socket head bolts.
Figure 4-10. Piston Seal Kit Installation
8. Using suitable protection, clamp the cylinder rod
in a vise or similar holding fixture as close to piston
as possible.
9. Carefully thread the piston on the cylinder rod
hand tight, ensuring that the o-ring and backup
rings are not damaged or dislodged.
10. Thread the piston onto the rod until it abuts the
spacer end and install the tapered bushing.
NOTE: When installing the tapered bushing, piston and
mating end of rod must be free of oil.
Figure 4-11. Rod Assembly Installation
11. Assemble the tapered bushing loosely into the pis-
ton and insert JLG capscrews (not vendor cap- 21. After the cylinder has been reassembled, the rod
screws) through the drilled holes in the bushing should be pushed all the way in (fully retracted)
and into the tapped holes in the piston. prior to the reinstallation of any holding valve or
12. Tighten the capscrews evenly and progressively in valves.
rotation to the specified torque value.
13. After the screws have been torqued, tap the
tapered bushing with a hammer (16 to 24 oz.) and
brass shaft (approximately 3/4" in diameter) as fol-
lows;
a. Place the shaft against the cylinder rod and in
contac t w it h the bushing in the spaces
between the capscrews.
b. Tap each space once; this means the tapered
bushing is tapped 3 times as there are 3 spaces
between the capscrews.

4-10 31215074
 SECTION 4 - HYDRAULICS

22. If applicable, install the cartridge-type holding NOTE: Reverse the procedure Steer Cylinder Piston Removal
valve and fittings in the rod port block, using new on page 4-8 for installing the steer cylinder piston.
o-rings as applicable. (See Table 4-3, Holding Valve
Torque Specifications). 24. Remove the cylinder rod from the holding fixture.
25. Position the cylinder barrel in a suitable holding
Table 4-2. Cylinder Piston Nut Torque Specifications fixture.

Nut Torque Setscrew NOTICE

Description
Value torque Value EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYL-
INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
250-300 ft. lbs.
Lift Cylinder N/A CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
(339-407 Nm)
CYLINDER BARREL SURFACES.
23. Push the piston onto the rod until it abuts the 26. With barrel clamped securely, and while ade-
spacer end and install the attaching nut. quately supporting the rod, insert the piston end
into the barrel cylinder. Ensure that the piston
Table 4-3. Holding Valve Torque Specifications loading o-ring and seal ring are not damaged or
dislodged.
Description Torque Value 27. Continue pushing the rod into the barrel until the
cylinder head gland can be inserted into the barrel
15 ft. lbs. cylinder.
Integrated Steer
(20 Nm)
28. If applicable, secure the cylinder head retainer
15 ft. lbs. using a suitable chain wrench.
Integrated Proportional Valve
(20 Nm) 29. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted)
15 ft. lbs. prior to the reinstallation of any holding valve or
Integrated Blocking Valve
(20 Nm) valves.
33 ft. lbs. 30. If applicable, install the cartridge-type holding
Relief valve and fittings in the port block using new o-
(45 Nm)
rings as applicable. Refer to Table 4-3, Holding
Coil Nuts Hand Tighten Valve Torque Specifications.

W HE N RE B U I LDI NG T HE C Y LI N DE RS , A PP LY M E D I U M
STRENGTH THREADLOCKING COMPOUND TO THE PISTON NUT
AND SETSCREW, THEN TORQUE PISTON NUT. REFER TO TABLE 4-
2, CYLINDER PISTON NUT TORQUE SPECIFICATIONS.

31215074 4-11
 SECTION 4 - HYDRAULICS

Pump Removal 3. If replacing filter, pull old filter off the end of the
tube and push new filter onto the end of tube.
4. Thoroughly clean the tank and clean any debris
from the magnet.
5. Wipe out tank with clean, lint free rag, taking care
not to introduce debris or dirt.
6. Replace the tank. Torque mounting bolts to 20-25
in-lb.
7. If only replacing the oil filter and maintenance is
complete, reinstall cylinder assembly on machine,
remove fill plug and refill tank with proper grade
of oil by using a funnel. Fill until oil weeps out of
opening.
8. Replace plug and torque to 40 ft. lbs. (56 Nm).

1. Place the pump/motor assembly on a clean work-

bench.
NOTE: Drain the hydraulic oil by carefully removing the oil
fill plug located on the left side of the hydraulic reser-
voir.

2. Remove the oil tank from the lift cylinder as fol-

lows:
a. Slowly loosen and remove the four bolts that
hold the tank on to the cylinder.
b. Carefully remove the tank from the valve body 9. To remove the oil pickup line, squeeze retainer and
taking care not to damage internal pickup slide outward.
tube or o-ring gasket on tank. 10. Replace the o-ring if necessary.
c. Place tank on a suitable work bench or work
area.
NOTE: The filter and bypass are located on the pickup tube
inside the tank.

The filter should be changed once a year.

4-12 31215074
 SECTION 4 - HYDRAULICS

11. Remove allen nut on the return/filter line and

rotate large retainer ring to remove return/filter NOTE: Be sure to remove and discard the plastic plug at the
line. oil inlet on the new pump before installing.
12. Replace the return/filter line oring if necessary.
13. With the return line and the pickup tube removed,
the pump can be removed.
14. Loosen and remove the two hexhead nuts from
the pump and block. Remove pump from valve
body.

15. Check oring on valve body and replace if neces-

sary before installing the new pump. Lubricate
orings before assembling.
NOTE: There are two orings used to seal the pump to the
valve body, one for the pump inlet (shown above)
and one on the pump boss around the drive coupler.

31215074 4-13
 SECTION 4 - HYDRAULICS

Motor Removal

2. Pull motor from valve body.

3. Once all maintenance is performed and lift cylin-
1. Remove the four bolts attaching the motor to the der assembly is reinstalled on the machine,
valve body. remove fill plug and refill tank with proper grade
of oil by using a funnel. Fill until oil weeps out of
opening.
4. Replace plug and torque to 40 ft. lbs.

4-14 31215074
 SECTION 4 - HYDRAULICS

TOP VIEW 2 3

2 2

7 8

ET RT

Figure 4-12. Lift Cylinder/Pump/Tank Assembly

Table 4-4. Valve Torque Values

Item Description Torque

1 Bi-directional Relief Valve 33 ft. lbs. (45 Nm)
2 Solenoid NA
3 Proportional Valve 15 ft. lbs. (20 Nm)
4 Check Valve 33 ft. lbs. (45 Nm)
5 Blocking Valve 15 ft. lbs. (20 Nm)
6 4 Way Directional Valve 15 ft. lbs. (20 Nm)
7 Extend Port NA
8 Retract Port NA

31215074 4-15
 SECTION 4 - HYDRAULICS

4
5 6

3
2
1

8 9

7 14 1930ES
ONLY

11
10
12
11
OR
11
12

20 13
18
19 14

17
15
16

22 OPPOSITE SIDE OF
24 CYLINDER PORT BLOCK
21

26
27
25
23

28

23

28
29

1. Proportional Valve 7. Spring 13. Locknut 19. Wear Ring 25. Check Valve
2. Emergency Release Assy. 8. Jam Nut 14. Piston 20. Spacer 26. Dowel Pin
3. Coil 9. Bushing 15. O-ring 21. Wiper 27. Directional Control Valve
4. Relief Valve 10. Barrel 16. Seal 22. O-ring 28. Coil
5. Pump 11. Wear Ring 17. Head 23. Bushing 29. Directional Control Valve
6. Filter 12. Seal 18. O-ring 24. Cylinder Rod

Figure 4-13. Lift Cylinder Assembly

4-16 31215074
 SECTION 4 - HYDRAULICS

15

14

14

16
1

17 18 13
11
10
9
12

4
5
3
7
8
6

14

14

MAF02570

1. Barrel 5. Seal 9. Piston 13. Nut 16. Capscrew

2. Rod 6. Bearing 10. Seal 14. Bushing 17. Capscrew
3. Cylinder Head 7. O-Ring 11. Wear Ring 15. Motor/Pump/Tank 18. Extension Plug
4. Dust Seal 8. O-Ring 12. O-Ring Assembly

Figure 4-14. Lift Cylinder Assembly (1930ES) (SH-PAC)

31215074 4-17
 SECTION 4 - HYDRAULICS

7
8

1
6
5

8 MAF02580

1. Barrel 3. Rod 5. Piston 7. Motor/Pump/Tank Assembly

2. Seal Kit 4. Cylinder Head 6. Screw 8. Bushing

Figure 4-15. Lift Cylinder Assembly (1930ES) (Serta)

4-18 31215074
 SECTION 4 - HYDRAULICS

1***** 2**
3*

4***** 5*****

6*

7******

*Torque to 33.2-36.9 ft. lbs. (45-50 Nm)

**Torque to 29.5-35.4 ft. lbs. (40-48 Nm)
***Torque to 28-33.2 ft. lbs. (38-45 Nm)
****Torque to 26.6-32.5 ft. lbs. (36-44 Nm)
*****Torque to 11.8-14.8 ft. lbs. (16-20 Nm)
******Torque to 2.2-3 ft. lbs. (3-4 Nm)
*******Torque to 29.5-36.9 ft. lbs. (40-45 Nm)

8*******

11**** 12****** 14**** 15***

13*
9******* 10** MAF02590

1. TR & TS Port 4. P Port 7. Steer Coil Nut 10. Steer Relief Valve 13. Lift Solenoid Valve
2. Relief Valve 5. T Port 8. Steer Port B 11. Steer Solenoid Valve 14. Lift/Steer Check Valve
3. Drain Plug 6. Filler Plug 9. Steer Port A 12. Lift Solenoid Valve Coil Nut 15. Descent Valve

Figure 4-16. Lift Cylinder Assembly - Motor/Pump/Tank Assembly

31215074 4-19
 SECTION 4 - HYDRAULICS

4-20 31215074
 SECTION 5 - JLG CONTROL SYSTEM

SECTION 5. JLG CONTROL SYSTEM

5.1 DIAGNOSTIC PORT 5.2 HAND HELD ANALYZER
The diagnostic port is located behind the battery cover To Connect the Hand Held Analyzer:
at the near the ground control station as shown below.
The MDI (Multifunction Digital Indicator) and the JLG 1. Connect the four pin end of the cable supplied
Hand-Held Analyzer can be connected at this port. with the analyzer, to the diagnostic port (refer to
Figure 5-1.) and connect the remaining end of the
cable to the analyzer.
NOTE: The cable has a four pin connector at each end of the
cable; the cable cannot be connected backwards.
2. Power up the Control System by turning the lower
key to the platform position and pulling both
emergency stop buttons on.

Figure 5-1. Diagnostic Port

Analyzer Display men u:

HELP:PRESS ENTER

Escape Key Enter Key

To return home or Stores and selects Top Level, Sub Level,
access previous menu and item menus

Up & Down Arrow Keys Left & Right Arrow Keys

Used to move between Top Level, Sub
Value Selector
Level, and item menus

Figure 5-2. Hand Held Analyzer

31215074 5-1
 SECTION 5 - JLG CONTROL SYSTEM

Using the Analyzer:

With the machine power on and the analyzer connected If ENTER is pressed again, the display moves to the fol-
properly, the analyzer will display the following: lowing display:

HELP: l og: ( 211)

1:STARTUP ( 2/ 1)
MENU:
HELP:PRESS ENTER

or

(machines with no MDI) (machines with an MDI)

LOGGED HELP
1: STARTUP (2/1): (Or last recorded fault)
HELP:
PRESS ENTER LOG: (211)
1: Power Cycle (Or last recorded fault)
At this point, using the RIGHT and LEFT arrow keys, you
can move between the top level menu items. To select a At this point, the analyzer will display the highest prior-
displayed menu item, press ENTER. To cancel a selected ity active fault, if any are present. You may scroll through
menu item, press ESC; then you will be able to scroll the fault logs to view what the last fifteen faults were.
using the right and left arrow keys to select a different Use the right and left arrow keys to scroll through the
menu item. fault logs. The active faults, are listed before the first
POWER CYCLE. To return to the top menu, press ESC two
The top level menus are as follows: times.
HELP When a top level menu is selected, a new set of menu
DIAGNOSTICS items may be offered; If for example you choose Person-
ACCESS LEVEL alities:
PERSONALITIES
MACHINE SETUP DRIVE
ACTIVATE TESTS LIFT
CALIBRATION STEER
GROUND
If you press ENTER, at the HELP:PRESS ENTER display,
Pressing ENTER with any of the above displayed menus,
and a fault is present, the analyzer display will scroll the
will display additional sub-menus within the selected
fault across the screen. If more than one fault is present
menu. In some cases the next level is the parameter or
only the highest priority fault will show. The other active
information to be changed. Refer to the flow chart for
faults are viewable in Logged Help. If there was no fault
what menus are available within the top level menus.
detected, the display will read:
You may only view the personality settings for selected
In platform mode, menus while in access level 2. Remember, you may
HELP: (001) always cancel a selected menu item by pressing the ESC
EVERYTHING OK, key.
In ground mode,
HELP: (002)
GROUND MODE OK

5-2 31215074
 SECTION 5 - JLG CONTROL SYSTEM

Changing the Access Level of the Hand Held

Analyzer:
When the analyzer is first connected, you will be in
access level 2 which enables you to only view most con- MENU:
figuration settings which cannot be changed until you ACCESS LEVEL 1
enter a password to advance to a lower level. This
ensures that a setting cannot be accidentally altered. To
change the access level, the correct password must be
entered. To enter the password, scroll to the ACCESS
LEVEL menu. For example:

MENU:
ACCESS LEVEL 2

MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings:

MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit
of the password, 3.
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the
password.
Use the UP or DOWN arrow key to enter the second
digit of the password which is 3.
Repeat this process until you have entered all five digits
of the password which is 33271.
Once the correct password is displayed, press ENTER.
The access level should display the following, if the pass-
word was entered correctly:

31215074 5-3
 SECTION 5 - JLG CONTROL SYSTEM

Adjusting Parameters using the Hand Held Machine Setup

Analyzer When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:
Once you have gained access to level 1, and a personal-
ity item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU-
LAR MACHINE CAN RESULT IN IMPROPER OPERATION.

PERSONALITIES:
DRIVE ACCEL 0.7s
GROUND ALARM:
1=DESCENT

PERSONALITIES:
DRIVE ACCEL 0.7s
GROUND ALARM:
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if 1=DESCENT
the UP arrow is pressed when at the maximum value The effect of the machine digit value is displayed along
nor will the value decrease if the DOWN arrow is with its value. The above display would be selected if
pressed and the value is at the minimum value for any the machine was equipped with a ground alarm and
particular personality. If the value does not change you wanted it to sound when driving. There are certain
when pressing the up and down arrows, check the settings allowed to install optional features or select the
access level to ensure you are at access level 1. machine model.
When selecting the machine model to match the size of
the machine, the personality settings will return to
default settings.
NOTE: Refer to Table 5-3, Machine Model Adjustment - Ver-
sion P1.14, and Table 5-4, Machine Configuration
Programming Information - Version P1.14 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.

5-4 31215074
 SECTION 5 - JLG CONTROL SYSTEM

5.3 TILT SENSOR CALIBRATION

CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PER- Be sure that the machine is parked and stowed on level
FORMANCE OF YOUR MACHINE. ground.
NOTE: Tilt Sensor Calibration can not be performed if the
NOTICE main contactor switch is open due to an alarm.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- 1. Enter Access Level 1 and go to the CALIBRATION/
TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASH- TILT SENSOR/LEVEL VEHICLE screen.
ING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ 2. Choose the right arrow key to view the raw, uncali-
ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOM- brated tilt sensor values. If either raw angle reads
MENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINI- ±5.0 or more, the machine is too unlevel and the
MUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE software will prohibit calibration. Therefore,
COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE attempt to dissect the three areas of error to find
SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF the primary contributor:
TIME PERIODS TO AVOID HEAVY SATURATION. a. Machine mounting and/or grade:
Try to measure the top of the Ground Control
The flash code is indicated on the face of the platform box for levelness. If unable to get a good read-
control box as shown: ing, unbolt the Ground Control box and check
the box’s mounting surface for levelness.
SYSTEM FAULT
b. Tilt sensor mounting on machine or wedged
crooked in control box:
If the machine mounting/grade appears
acceptable, remove and open the Ground Con-
trol box carefully. Observe whether the tilt sen-
sor is properly seated.
c. Tilt sensor has developed an offset shift:
Remove the tilt sensor from the Ground Con-
trol box but keep both the tilt sensor and
Ground Control box electrically connected.
Diagnostic Trouble Codes are indicated on the MDI for Level one axis of the tilt sensor and observe
those machines that are equipped with an MDI. (refer to the raw reading (should be within ± 2.0). Do
Section 3.7). the same for the other axis. If either axis is
greater than ± 2.0, replace the tilt sensor.
NOTE: Flash codes and DTC’s are also displayed on the
handheld analyzer. For descriptions see, Table 5-2, NOTE: Check that the tilt switch is properly set by referring
Flash Code Listing. to the Tilt Settings table in Section 1 of this manual.

Failure Troubleshooting for the Field

Some possible reasons that the tilt sensor will not cali-
brate are:
a. The surface the machine is sitting on is off level
by a few degrees (flat doesn’t imply level; park-
ing lots are often not level).
b. The tilt sensor has failed one or both of the
channels (X axis and Y axis).
c. Tilt sensor has moisture intrusion that has
shifted its output.
d. Water and/or corrosion in the box has cor-
rupted electrical connections or caused a tilt
sensor or ground cont rol b oard failure
(observe any cracks in the box).
e. The Ground Control Box, as mounted on the
machine, does not allow the tilt sensor to be
level.

31215074 5-5
 SECTION 5 - JLG CONTROL SYSTEM

For the following troubleshooting steps, a bubble level 5.4 TILT SENSOR ELECTRICAL EVALUATION
(smaller is better) will be needed and the machine must
be on a level surface: This basic check using the JLG Analyzer can be used to
test the Tilt Sensor.
1. On the Analyzer, go to the Diagnostics/System and
read the tilt angle. If either angle reports +20.0°,
• If angle measurements read +20.0, then a sensor/
there is an electrical/electronic failure (tilt sensor,
wiring/connector fault exists. If the readings inter-
control board, electrical connections).
mittently display expected angles, then there is likely
a. Take the Ground Control box off of the a wiring/connector problem and not a failed sensor.
machine and open the rear cover. In either case, open the ES Ground box. Disconnect
b. Disconnect the sensor and clean any corrosion the sensor, check the wire terminations, and clean
off of the tilt sensor and control board connec- any corrosion on the tilt sensor and control board
tions. connections. Reconnect and test. If the fault persists,
c. Reassemble and test. If fault persists, replace replace the tilt sensor and return the faulty tilt sensor
tilt sensor. to JLG with a detailed description of the diagnostic
steps taken.
2. If the Analyzer displays angles other than +20.0°,
attempt to calibrate. If machine won’t calibrate, 5.5 ELEVATION ANGLE SENSOR ELECTRICAL
note the reason displayed on Analyzer:
EVALUATION
a. SENSOR FAILURE – tilt sensor internal fre-
quency is out of range (replace sensor). These basic checks using the JLG Analyzer can be used
b. NOT LEVEL - tilt sensor has either developed an to test the Elevation Angle Sensor. If the problem is still
offset or it is too unlevel as mounted on the occurring, perform the Tilt vs. Allowed Height Evalua-
machine. tion described below.

• On a level surface, with the Analyzer under DIAG-

NOSTICS/ELEV SENSOR, verify that the elevation
angle sensor voltage increases (ranges from 0.2V-
0.8V to 3.6V-4.2V) with platform height. If not,
check the sensor mounting. If necessary, unbolt sen-
sor and rotate by hand while monitoring with the
Analyzer to check the integrity of the sensor output.
• For machines equipped with an elevation proxim-
ity switch, if the Elevation Sensor appears satis-
factory, verify that the Elevation Prox switch is
opening and closing appropriately by watching
the change of state between the stowed and ele-
vated positions (monitor PROX SWITCH under DIAG-
NOSTICS/ELEV SENSOR). If a change of state is not
observed, check prox mounting and operability by
placing metal in front of the prox sensor face.

5-6 31215074
 SECTION 5 - JLG CONTROL SYSTEM

Tilt vs. Allowed Height Evaluation Table 5-1. Tilt Settings

First, find a level surface (not just flat like a parking lot; Tilt Setting Tilt Setting Maximum Platform
must be level). The surface should be a plane in which Model
(front to back) (side to side) Elevation
the wheels are within 0°±0.2°. Find this surface by taking
a digital level and measuring the areas on which the 1.5° 18.75 ft (5.7 m)
wheels would rest in both the X and Y directions. Mark 2° 14 ft (4.3 m)
1930ES 3°
the locations and drive the machine to these points. If a 2.5° 11 ft (3.4 m)
level surface can not be found, flat shims or plates may 3° 9 ft (2.7 m)
be place under the wheels to create a level plane for the 1.5° 20 ft (6 m)
wheels. 2° 15 ft (4.5 m)
2032ES 3°
2.5° 12 ft (3.7 m)
In determining the existing tilt angle, read the angle on
3° 10 ft (3 m)
the Analyzer under DIAGNOSTICS/SYSTEM. Do not place
a hand-held level on the machine to determine whether 1.5° 25.4 ft (7.7 m)
the machine is level and lifting to the appropriate 2° 20 ft (6 m)
2632ES 3°
height. Such a measurement will likely be different than 2.5° 16 ft (4.9 m)
the Ground box/tilt sensor angle reading due to manu- 3° 13 ft (4 m)
facturing and mounting tolerances. The tilt angle in 2° 26 ft (7.9 m)
both directions should read within ±0.5° while on a level 2646ES 3° 2.5° 22 ft (6.7 m)
surface. If not, then either the machine has a drifting tilt 3° 20 ft (6 m)
sensor or has been erroneously re-calibrated since the
original factory calibration. 2° 31.75 ft (9.7 m)
3246ES 3° 2.5° 22 ft (6.7 m)
Check the service records to determine whether a re cal- 3° 20 ft (6 m)
ibration has been performed. If so, re-calibrate on the
level surface. If there is no record of an earlier calibra- NOTE: For Japanese specification machines labeled "Minis-
tion, we must assume that the sensor output has drifted. try of Labor Notification #70," the Tilt Setting is 5
Therefore, replace the sensor and return to JLG with a degrees (front to back and side to side) regardless of
detailed troubleshooting description. elevated platform height.
NOTE: There is a rare case in which an attempted calibra- If the machine does not appear to track the lift cutout
tion will be unsuccessful for machines with Ground heights and no fault exists as described above, stow the
module software version P1.5 or earlier. If this occurs machine and re calibrate the Elevation Sensor.
while performing a calibration, the Analyzer will dis-
play:
LEVEL VEHICLE
TILT +20.0 +20.0
and the following fault will also be logged.
TILT SENSOR NOT CALIBRATED (2/3) [DTC 811]
If no other faults have been logged since the last
startup, this fault indicates that the software needs to be
updated to P1.6 or later. Update the software and con-
tinue troubleshooting evaluation before replacing any
components.
If the tilt sensor readings are within range for a level
machine, compare the allowed Tilt vs. Height in the
chart below. Being within 6” of the target height is con-
sidered acceptable.

31215074 5-7
 SECTION 5 - JLG CONTROL SYSTEM

5.6 ELEVATION SENSOR CALIBRATION 5.7 UPDATING SOFTWARE

Updating the ground module software requires a laptop
NOTICE computer, connecting cable, and software update cd.
MACHINE MUST BE ON LEVEL GROUND BEFORE ELEVATION SEN- Contact JLG Industries to acquire the software cd.
SOR CAN BE SET.
Before updating the software, use the Hand-held Ana-
1. Be sure that the machine is parked and platform lyzer to view the machine’s settings (MACHINE SETUP
stowed on level ground. and PERSONALITIES) (refer to Figure 5-3 and Figure 5-4
for Analyzer Flow Chart). It is important to write down
2. Attach the analyzer near the ground control sta- the settings to verify they are the same after software
tion. update is complete.
3. Go to Access Level 1 and scroll through to CALI-
BRATION. NOTE: Software update must be done with the machine
powered in Ground Mode.
4. Under CALIBRATION, go to SET STOW ELEV.
5. Press ENTER for YES to set the stowed height for 1. Disconnect analyzer from diagnostic port.
the elevation sensor. 2. Using the laptop connector cable, connect the lap-
6. Fully raise the platform. top to the diagnostic port.
7. Under CALIBRATION, go to SET MAX ELEV. 3. Run the software update cd.
8. Press ENTER for YES to set the maximum height for a. When the JLG Reprogramming Tool dialogue
the elevation sensor. box appears, click on the Program button.
b. Another dialogue box will appear asking if you
NOTE: Check the elevation sensor by lifting the scissor arms, want to overwrite the current software version.
from the platform, and driving until the drive speed Click YES.
cuts back. Refer to High Drive Speed Cutout for
proper speed cut out height. 4. After software update is complete, disconnect
computer from diagnostic port.
5. Reconnect the hand-held analyzer to the diagnos-
tic port.
a. Enter Access Level 1 password; 33271
b. Scroll to MACHINE SETUP. Change MODEL
NUMBER to a different model, but immediately
change it back to the proper setting. Do the
same for MARKET. This will ensure the settings
are carried over to all parameters.
c. Scroll through the settings to verify they are
the same as before the software update.
6. Disconnect Analyzer.
7. Software update is complete.

5-8 31215074
 SECTION 5 - JLG CONTROL SYSTEM

5.8 TROUBLESHOOTING NOTE: It may also be helpful to do the following for inter-
mittent or difficult problems: run a system test, ANA-
It should be noted that there is no substitute for a thor- LYZER -> SYSTEM TEST; check the machine
ough knowledge of the equipment and related systems. personalities, ANALYZER ->PERSONALITIES (refer to
Table 5-3, Machine Model Adjustment - Version
It should be recognized that the majority of the prob-
P1.14); and check the machine setup, ANALYZER ->
lems arising in the machine will be centered in the
MACHINE SETUP (refer to Table 5-4, Machine Config-
hydraulic and electrical systems.
uration Programming Information - Version P1.14).
The first rule for troubleshooting any circuit that is
hydraulically operated and electrically controlled is to These below flash codes apply only to machines
determine if the circuit is lacking hydraulic oil and elec- without the MDI (refer to Section 3.7, MDI (Multifunc-
trical control power. This can be ascertained by overrid- tion Digital Indicator) and Brake Release). For
ing the bypass valve (mechanically or electrically) so machines with the MDI, refer to Section 6.
that oil is available to the function valve, then overriding
the function valve mechanically. If the function per- Anytime a problem is resolved, recycle the EMS.
forms satisfactorily, the problem exists with the control
circuit.

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code

Help Messages with no flash code may occur during normal operation and explain various vehicle interlocks.
Platform is elevated and the chassis is not level.
Platform Position Sensor (PPS) elevation status is elevated and
the vehicle is tilted and machine setup’s TILT CUTOUT is config-
0 0 ALARM SOUNDING--TILTED AND ABOVE ELEVATION
ured correctly, see Table 5-4, Machine Configuration Program-
ming Information - Version P1.14.
No motion restrictions.
Platform is elevated and the machine is in the drive mode of
operation.
In platform mode, Platform Position Sensor (PPS) elevation
0 0 DRIVING AT CUTBACK -- ABOVE ELEVATION
status is elevated and the vehicle is driving and the drive speed
is drive elevated.
Driving at elevated speed.
Driving is not possible since the platform is elevated and the
chassis is not level.
In Platform Mode, Platform Position Sensor (PPS) elevation
0 0 DRIVE & LIFT UP PREVENTED -- TILTED & ELEVATED status is elevated and the vehicle is tilted and machine setup’s
TILT CUTOUT is configured correctly, see Table 5-4, Machine
Configuration Programming Information - Version P1.14.
Drive prevented.

Applicable to 3246ES configured for the Zone A/B Capacity

Selection, and operating on Zone A. The vehicle has reached
the maximum height and further lift up motion is not possible.
0 0 LIFT UP PREVENTED -- MAX HEIGHT ZONE A
Machine Setup’s CAPACITY SELECT is 1=ZONE A/B and Machine
Setup’s MODEL is 3246ES and Zone A Lift Up=False.
Lift up prevented.

31215074 5-9
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
While stowed, drive speed is reduced (due to lower ground
clearance) since the control system detected that the pot-hole
Clear the obstacle blocking the
protection mechanism is deployed (failed to retraced).
pot-hole protection mecha-
In platform mode with a healthy elevation sensor, elevation
nism, repair the mechanical
0 0 DRIVING AT CUTBACK -- POTHOLE STILL ENGAGED sensor less than 0.15V and the elevation prox closed and pot-
problem, re-adjust the pot-hole
hole protection’s PHP switches detect down.
limit switches, or repair the wir-
In platform mode with an unhealthy elevation sensor, the ele-
ing to correct the problem.
vation prox is closed AND pot-hole protection’s PHP switches
detect down.
Check batteries charge, condi-
After 2 hours without activity, the control system enters a low- tion, etc. Normal operation
0 0 FUNCTIONS LOCKED OUT -- SYSTEM POWERD DOWN
power state to preserve battery charge. should resume after a power
cycle.
The Drive Cutout functionality is enabled, and the platform is
elevated above the calibrated cutout height.
Drive Cutout is set to 1=YES AND the Elevation Sensor is
DRIVE PREVENTED -- ELEVATED AND ABOVE DRIVE CUT- Check elevation switches
0 0 “Healthy”AND the Elevation Sensor’s Zeroed Voltage is Greater
OUT HEIGHT Check pothole switches.
Than the Calibrated Drive Cutout Voltage.
Refer to Drive Cutout Functionality.

Help messages with the 2-1 flash code occur during after power-up of the vehicle control system.
This help message is issued at each power-up. This serves to
indicate which messages have been recorded in logged help
2 1 STARTUP since the last power-up event.
No motion restrictions.
No motions restricted.
The platform and ground mode inputs from the keyswitch are
active at the same time. The control system will default to
ground mode when if this happens. The keyswitch and wiring Re-cycle power once the prob-
KEYSWITCH FAULTY -- PLATFORM & GROUND ACTIVE
2 1 inside the ground control box should be examined / repaired. lem has been resolved to clear
TOGETHER
Platform EMS digital input energized and ground mode select this difficulty.
digital input energized.
Default to ground mode operation and lift up prevented
Help messages with the 2-2 flash code indicate difficulty with the platforms controls.
Horn switch in the platform control box was closed during
power-up.
In platform mode, the Indoor/Outdoor switch digital input is Release or repair the switch to
2 2 FUNCTION PROBLEM -- HORN PERMANENTLY SELECTED
energized and power-up is active. Retained until either is clear the message.
momentarily de-energized.
Previously selected Indoor/Outdoor mode maintained.

Indoor / Outdoor switch in the platform control box was closed

during power-up.
FUNCTION PROBLEM -- INDOOR / OUTDOOR PERMA- In Platform Mode, the Indoor / Outdoor Switch Digital Input is Release or repair the switch to
2 2
NENTLY SELECTED Energized and Power-up is Active. Retained until Digital Input clear the message.
is momentarily De-energized.
Previously selected Indoor / Outdoor Mode maintained

5-10 31215074
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The Drive - Lift selector switch indicates that both functions are
selected simultaneously.
In Platform Mode, the Drive and Lift Digital Inputs are Ener- Repair the wiring or switch to
2 2 FUNCTION PROBLEM -- DRIVE & LIFT ACTIVE TOGETHER
gized at the same time. Retained until either is momentarily clear the message.
De-energized.
Drive, Steer, & Lift Prevented
Steer left switch in the platform control box was closed during
power-up.
FUNCTION PROBLEM -- STEER LEFT PERMANENTLY In Platform Mode, the Left Steer Digital Input Switch is Ener- Release or repair the switch to
2 2
SELECTED gized AND Power-up is Active. Retained until Digital Input is clear the message.
momentarily De-energized.
Steer & Drive Prevented
Steer right switch in the platform control box was closed
during power-up.
FUNCTION PROBLEM – STEER RIGHT PERMANENTLY In Platform Mode, the Right Steer Digital Input Switch is Ener- Release or repair the switch to
2 2
SELECTED gized and Power-up is Active. Retained until Digital Input is clear the message.
momentarily De-energized.
Steer & Drive Prevented.
The joystick (accelerator) wiper signal input is outside the
The wiper wire being off, the
acceptable voltage range.
wiper wire shorted to +B, or the
In Platform Mode, the Joystick (accelerator) Analog Input
2 2 ACCELERATOR FAULTY – WIPER OUT OF RANGE wiper wire shorted to –B
Switch is > 4.50V OR < 0.50V. Retained until Analog Input is
(ground) could cause this diffi-
measured within proper range.
culty.
Drive, Steer, & Lift Prevented.
Both the steer left and steer right inputs are closed as the same
time.
A short in the steer switch wir-
ACCELERATOR FAULTY – STEER SWITCHES ACTIVE In Platform Mode, the Steer Left Digital Input is Energized and
2 2 ing or a failed steer switch can
TOGETHER the Steer Right Digital Input is Energized. Retained until either
cause this difficulty.
Digital Input is momentarily De-energized.
Drive & Steer Prevented.
Selected function (drive or lift) is not allowed because the joy-
stick (accelerator) was not centered at power-up.
In Platform Mode, scaled Joystick (accelerator) position was Return joystick to center
2 2 FUNCTION LOCKED OUT – ACCELERATOR NOT CENTERED
something other than 0% AND Power-up was Active. Retained momentarily and re-initiate.
until the Joystick is momentarily centered.
Drive, Steer, & Lift Prevented.
Trigger switch in the platform control box was closed at power-
up.
Release switch or repair the
FUNCTION PROBLEM – TRIGGER PERMANENTLY CLOSED In Platform Mode, the Trigger Digital Input was Energized AND
2 2 switch / wiring to clear the diffi-
Power-up was Active. Retained until the Trigger Digital Input is
culty.
momentarily De-energized.
Drive, Steer, & Lift Prevented.
Trigger switch in the platform control box was closed for more
than ten seconds while the joystick (accelerator) was in the
neutral position (centered).
In Platform Mode, the Trigger Digital Input was Energized for Release switch or repair the
2 2 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL 10,000mS AND Drive was In-Active AND Lift was In-Active. switch / wiring to clear the diffi-
Retained until the Trigger Digital Input is momentarily De- culty.
energized.
Drive, Steer, & Lift Prevented.

31215074 5-11
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
Help messages with the 2-3 flash code indicate difficulty with the ground controls.
Lift switch (up or down) in the ground control box was closed
during power-up.
In Ground Mode, [Lift Up Digital Input is Energized or Lift Down
FUNCTION PROBLEM – LIFT PERMANENTLY SELECTED Release or repair the switch to
2 3 Digital Input is Energized] AND Power-up is Active. Retained
clear the message.
until the respective Digital Input is momentarily De-ener-
gized.
Lift Prevented
In ground mode, the control system has detected the lift up
and down are active simultaneously.
Check the lift switch and associ-
In Ground Mode, Ground Lift Up Digital Input is Energized and
2 3 GROUND LIFT UP/DOWN ACTIVE TOGETHER ated wiring in the ground con-
Ground Lift Down Digital Input is Energized. Retained until
trol box.
both the Digital Inputs are momentarily De-energized.
Lift Prevented
No signal from the tilt sensor mounted inside the ground con-
trol box.
Transitions on the Tilt X OR Tilt Y signals not detected for
Check wiring and plug connec-
NO DATA FROM TILT SENSOR – NOT CONNECTED OR 2000mS. Retained until transitions on both are sensed.
2 3 tions at the tilt sensor and at the
FAULTY Vehicle assumed Tilted (+20.0’X, +20.0’Y); Drive Stowed
ground control board.
Demand limited as in Worst-Case Slope Descent Functionality
for both Forward and Reverse
Drive will be slow in the Forward direction.
The Tilt Sensor’s Calibration EEPROM is set to the signature
implanted by the In-Circuit Test Fixture. Retained until Calibra-
tion EEPROM is over-written by a valid calibration. Calibrate the Tilt Sensor using
2 3 TILT SENSOR NOT CALIBRATED Vehicle assumed Tilted (+20.0’X, +20.0’Y); Drive Stowed the calibration procedure to
Demand limited as in Worst-Case Slope Descent Functionality clear the message.
for both Forward and Reverse
Drive will be slow in the forward direction.
Check if the lift switch is
obstructed or jammed. Check
FUNCTION PROBLEM -- BRAKE RELEASE PERMANENTLY The ground control box lift switch was closed up or down,
2 3 the lift switch signal and wiring
SELECTED during power-up in ground mode.
to the ground board. Replace
ground board.
Help messages with the 2-5 flash code indicate that a function is prevented due to a cutout.

The input voltage from the sensor that measures lower arm
motion is outside acceptable range. This may be caused by Check mounting, review sensor
ELEV ANGLE SENSOR FAULTY – NOT MOUNTED OR VOLT- improper sensor mounting, difficulty with the sensor wiring, wiring against the electrical
2 5
AGE OUT OR RANGE or a faulty sensor. schematic, or replace the sensor
The elevation sensor is unhealthy to clear the message.
Platform height assumed to be full elevation.

5-12 31215074
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The Elevation Sensor’s Calibration EEPROM is set to the signa-
ture implanted by the In-Circuit Test Fixture. Retained until
Calibration EEPROM is over-written by a valid calibration.
Platform Height assumed to be Full Elevation.
The Elevation Proximity Switch is Open to indicate that the Calibrate the elevation angle
2 5 ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED Platform is Elevated, but the Elevation Sensor’s Voltage indi- sensor using the calibration pro-
cates that the Platform is Stowed. To be conservative, the con- cedure to clear the message.
trol system will assume that the Platform is Elevated.
Elevation Sensor is “Healthy”AND the Elevation Sensor’s
Zeroed Voltage is < 0.04V AND the Elevation Prox Switch is
Open for 2000mS. Retained until situation changes.
Driving is not possible since the vehicle is charging and it is con-
figured to only allow lifting.
In Platform Mode, the Battery Charger is Charging AND the
2 5 DRIVE PREVENTED – CHARGER CONNECTED Disconnect battery charger
Drive / Lift Select Toggle is set to Lift AND Machine Setup’s
CHARGE INTERLOC is set to 0=DRIVE ONLY.
Drive & Steer Prevented
Driving and lifting are not possible since the vehicle is charging
and it is configured to prevent all motion.
In Platform Mode, the Battery Charger is Charging AND the
2 5 DRIVE & LIFT UP PREVENTED – CHARGER CONNECTED Disconnect battery charger
Drive / Lift Select Toggle is set to Lift AND Machine Setup’s
CHARGE INTERLOC is set to 1=DRV & LIFT UP.
Drive & Lift Up Prevented.
While the Load Sensing System is enabled, the platform load
measured by the Load Sensing System is excessive. Functions
from platform control are prevented, and functions from
ground control may be prevented, depending on machine con-
Remove excess weight from
figuration.
2 5 PLATFORM OVERLOADED platform.
The Load Sensing System Functionality’s Overload is True AND
[Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT
ALL].
Drive, Steer, & Lift Prevented (except 3246ES CE, Indoor Mode,
Height >24 Ft and < 26Ft, Lift Dn allowed).

While elevated, driving is not possible since the control system

detected that the pot-hole protection mechanism failed to
deploy.
Clear the obstacle blocking the
In Platform Mode with a Healthy Elevation Sensor, the Eleva-
pot-hole protection mecha-
tion Sensor Voltage > 0.15V AND Pot-Hole Protection’s PHP
nism, repair the mechanical
2 5 DRIVE PREVENTED – POTHOLE NOT ENGAGED Switches detect Up.
problem, re-adjust the pot-hole
In Platform Mode with an Unhealthy Elevation Sensor, the Ele-
limit switches, or repair the wir-
vation Prox Sensor is Open (no Arm Detected) AND Pot-Hole
ing to correct the problem.
Protection’s PHP Switches detect Up.
Drive & Steer Prevented.

31215074 5-13
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The Elevation Proximity Switch is closed to indicate that the
platform is stowed, but the elevation sensor’s voltage indicates
that the platform is elevated. To be conservative, the control
ELEV PROX PERMANENTLY CLOSED – CHECK PROX AND system will assume that the platform is elevated, and the drive
Check elevation switches.
2 5 ANGLE ADJUSTMENT speed will be restricted to elevated.
Replace if necessary.
Elevation Sensor is “Healthy”AND the Elevation Sensor’s
Zeroed Voltage is > 0.15V AND the Elevation Prox Switch is
Closed for 2000mS. Retained until situation changes.
Refer to Platform Position Sensor Functionality.
The manual brake release has been activated to allow the vehi-
DRIVE & LIFT PREVENTED – BRAKES ELECTRICALLY
cle to be towed. Disengage the manual brake
2 5 RELEASED FOR TOWING
Brake release digital input is energized release.
Drive and Lift Prevented
The Drive Cutout functionality is enabled, and the platform is
elevated above the calibrated cutout height.
DRIVE PREVENTED – ELEVATED ABOVE DRIVE CUTOUT Drive Cutout is set to 1=YES AND the Elevation Sensor is Check elevation switches
2 5
HEIGHT “Healthy”AND the Elevation Sensor’s Zeroed Voltage is Greater Check pothole switches.
Than the Calibrated Drive Cutout Voltage.
Refer to Drive Cutout Functionality.
Check ANALYZER -> MACHINE
MODEL CHANGED -- HYDRAULICS SUSPENDED - CYCLE
2 5 The model selection has been changed. SETUP -> MODEL NUMBER.
EMS
Replace ground board.
Ensure vehicle is not stuck on
something preventing move-
While driving on a level surface, armature current was > 150A
2 5 DRIVE PREVENTED -- BRAKES NOT RELEASING ment. Check/repair drive motor
for five seconds. Brakes assumed to not be releasing properly.
wiring, brakes or mechanical
issues.
Help messages with the 3-1 flash code indicate that a contactor did not close when energized.
The Power Module’s line contactor drive circuitry passed
power-up self-tests, but the line contactor did not close when
Refer to CANbus documentation
energized.
3 1 OPEN CIRCUIT LINE CONTACTOR for Power Module Message -
The Power Module is reporting a “Contactor Did Not Close”
Status.
Fault Code (15d).
Drive, Steer, & Lift Up Prevented.
The Power Module’s Line Contactor drive circuitry failed to
energize during power-up self-tests. Refer to CANbus documentation
3 1 CONTACTOR DRIVER PERMANENTLY OFF The Power Module is reporting a “Contactor Driver 1 Perma- for Power Module Message -
nently Off”Fault Code (22d). Status.
Drive, Steer, & Lift Up Prevented.
Help messages with the 3-2 flash code indicate that a contactor did not open when de-energized.

The Power Module’s Line Contactor Drive Circuitry passed

power-up self-tests, but the line contactor did not open when
Refer to CANbus documentation
de-energized.
3 2 LINE CONTACTOR MISWIRED ON OR WELDED for Power Module Message -
The Power Module is reporting a “Contactor Welded”Fault
Status.
Code (14d).
Drive, Steer, & Lift Up Prevented.

5-14 31215074
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The Power Module’s Line Contactor Drive Circuitry failed to de-
energize during power-up self-tests.
Refer to CANbus documentation
The Power Module is reporting a “Contactor Driver 1 Perma-
3 2 CONTACTOR DRIVER PERMANENTLY ON for Power Module Message -
nently On”Fault Code (23d). Refer to CANbus documentation
Status.
for Power Module Message – Status.
Drive, Steer, & Lift Up Prevented.
Help messages with the 3-3 flash code indicate an output driver problem.
NOTE: Certain output driver problems cannot be detected because stimulation of the load could result in safety con-
cerns or annoyance (brake open circuit, lift down open circuit, ground alarm open circuit). 3-3 help messages
shall be latched until the next power cycle.
Voltage was detected on the brake solenoid when the output
driver was commanded off during power-up.
BRAKE SHORT TO BATTERY
3 3 Brake INPUT driven Low AND Brake STAT detected Low during
power-up.
Drive, Steer, & Lift Prevented.
Current flow to the brake solenoid was not detected during
normal brake operation.
3 3 BRAKE OPEN CIRCUIT Brake INPUT driven High (normal operation) AND Brake STAT
detected Low.
Drive & Steer Prevented
Voltage was detected on the lift up solenoid when the output
driver was commanded off during power-up.
3 3 LIFT UP SHORT TO BATTERY Lift Up INPUT driven Low AND Lift Up STAT detected Low during
power-up.
Drive, Steer, & Lift Up Prevented.
Current flow to the lift up solenoid was not detected during
power-up.
3 3 LIFT UP OPEN CIRCUIT Lift Up INPUT driven High (momentarily) AND Lift Up STAT
detected Low during power-up.
No motion interlocks.
Voltage was detected on the lift down solenoid when the out-
put driver was commanded off during power-up.
3 3 LIFT DN SHORT TO BATTERY Lift Down INPUT driven Low AND Lift Down STAT detected Low
during power-up.
No motion interlocks.
Current flow to the lift down solenoid was not detected during
normal lift down motion.
3 3 LIFT DN OPEN CIRCUIT Lift Down INPUT driven High (normal operation) AND Lift
Down STAT detected Low.
Lift Up Prevented.

Voltage was detected on the steer left solenoid when the out-
put driver was commanded off during power-up.
Left Turn INPUT driven Low AND Left Turn STAT detected Low
3 3 STEER LEFT SHORT TO BATTERY
during power-up.
Drive & Steer Prevented.

31215074 5-15
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
Current flow to the steer left solenoid was not detected during
power-up.
3 3 STEER LEFT OPEN CIRCUIT Left Turn INPUT driven High (momentarily) AND Left Turn STAT
detected Low during power-up.
Drive & Steer Prevented.
Voltage was detected on the steer right solenoid when the out-
put driver was commanded off during power-up.
3 3 STEER RIGHT SHORT TO BATTERY Right Turn INPUT driven Low AND Right Turn STAT detected
Low during power-up.
Drive & Steer Prevented.
Current flow to the steer right solenoid was not detected
during power-up.
3 3 STEER RIGHT OPEN CIRCUIT Right Turn INPUT driven High (momentarily) AND Right Turn
STAT detected Low during power-up.
Drive & Steer Prevented.
While the load sensing system was enabled, voltage was
detected on the ground control box’s overload lamp when the
output driver was commanded off during power-up.
3 3 GROUND OVERLOAD LAMP SHORT TO BATTERY Ground Overload INPUT driven Low AND Ground Overload STAT
detected Low during power-up AND [Machine Setup’s LOAD
set to 1=CUTOUT PLT OR 2=CUTOUT ALL].
No motion interlocks.
While the Load Sensing System was enabled, current flow to
the ground control box’s overload lamp was not detected
during power-up.
Ground Overload INPUT driven High (momentarily) AND
3 3 GROUND OVERLOAD LAMP OPEN CIRCUIT
Ground Overload STAT detected Low during power-up AND
[Machine Setup’s LOAD set to 1=CUTOUT PLT OR 2=CUTOUT
ALL].
No motion interlocks.
While enabled, voltage was detected on the ground alarm
when the output driver was commanded off during power-up.
GROUND ALARM SHORT TO BATTERY Ground Alarm INPUT driven Low AND Ground Alarm STAT
3 3
detected Low during power-up AND [Machine Setup’s
GROUND ALARM set to 1=DECENT OR 2=MOTION].
No motion interlocks.
Check for continuity through
The ground board detected voltage while the left brake was this circuit. Inspect the wiring
3 3 LEFT BRAKE SHORT TO BATTERY
commanded off. for physical damage.
Replace ground board.
Check for continuity through
Current flow to the left brake solenoid was not detected during this circuit. Inspect the wiring
3 3 LEFT BRAKE OPEN CIRCUIT
normal left brake operation. for physical damage.
Replace ground board.

Check for continuity through

Voltage was detected on the right brake solenoid when the this circuit. Inspect the wiring
3 3 RIGHT BRAKE SHORT TO BATTERY
ground board output was commanded off during power-up. for physical damage.
Replace ground board.

5-16 31215074
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
Check for continuity through
The ground board did not detect current flow to the right brake this circuit. Inspect the wiring
3 3 RIGHT BRAKE OPEN CIRCUIT
during normal operation. for physical damage.
Replace ground board.
Help messages with the 4-2 flash code indicate a thermal problem.
The Power Module for drive, steer, and lift up has reached ther-
POWER MODULE TOO HOT – PLEASE WAIT
4 2 mal cutout. Allow to cool by powering down.
The power Module is reporting a "Unit Too Hot" fault code.
The drive portion of the Power Module has reached thermal
DRIVING AT CUTBACK -- POWER MODULE CURRENT limit. Allow to cool by waiting for temperature to fall.
4 2 LIMIT
The Power Module is reporting a "I2T Drive Current LImit" fault
code.
The lift up portion of the power module has reached thermal
LIFT UP AT CUTBACK -- POWER MODULE CURRENT LIMIT limit. Allow to cool by waiting for temperature to fall.
4 2
The POwer Module is reporting "I2Pump Current LImit" fault
code.
Help messages with the 4-4 flash code indicate a battery supply problem.
Battery Voltage momentarily dropped below 14.5V. With a
low battery charge, this can occur during heavy current
BATTERY VOLTAGE TOO LOW – SYSTEM SHUTDOWN demand due to drive, steer, or lift up. Recharge batteries or check for
4 4
The Power Module is reporting a “Low Battery”Fault Code damaged batteries.
(7d).
Drive, Steer, & Lift Up Prevented
The Power Module momentarily measured excessively high
battery voltage (>37.0v) and the ground module de-ener-
gized the ignition relay to protect system devices.
The Power Module is reporting a “High Battery”Fault Code (8d) This may be due to improper
BATTERY VOLTAGE TOO HIGH – SYSTEM SHUTDOWN
4 4 OR a “High Battery without Line”Fault Code (10d). In response, battery charging or incorrect
the Ground Module shall de-energize the Ignition Relay and voltage batteries being used.
suppress all Help Messages caused by the lack of Ignition Sig-
nal. This fault is latched until the next power-cycle.
Drive, Steer, & Lift Prevented.
While the Load Sensing System is enabled, the Load Sensing
System module measured battery voltage >34.0Vdc, which
may compromise ability to predict weight. This may be due to improper
LSS BATTERY VOLTAGE TOO HIGH
4 4 LSS Module Message – Status Message (0x81) is reporting battery charging or incorrect
“BATT TOO HIGH”AND [Machine Setup’s LOAD is set to 1=CUT- voltage batteries being used.
OUT PLT OR 2=CUTOUT ALL]. Vehicle assumed to be Over-
loaded.
While the Load Sensing System is enabled, the Load Sensing
System module measured battery voltage <9.0vdc, which
may compromise ability to predict weight. With a low battery
charge, this can occur during heavy current demand due to
LSS BATTERY VOLTAGE TOO LOW drive, steer, or lift up. Recharge batteries or check for
4 4
LSS Module Message – Status Message (0x81) is reporting damaged batteries.
“BATT TOO LOW”AND [Machine Setup’s LOAD is set to 1=CUT-
OUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.

31215074 5-17
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
Help messages with the 6-6 flash code indicate vehicle communication (CANbus) problems. These faults shall not be latched. Normal operation shall
resume if difficulty is resolved.
The control system failed to receive messages from the Power
Module.
Check wiring at the ground con-
CANBUS FAILURE: POWER MODULE Power Module Message – Status (0x24) not received for
6 6 trol box and power module.
1000mS or Power Module is reported a “CANbus Bus Difficulty”
Recycle power to clear difficulty.
Fault Code (0x09).
Drive, Steer, & Lift Up Prevented.
In Platform Mode, the control system failed to receive mes-
sages from the platform module.
Check wiring at the platform
Digital Input Message – Motion (0x00) not received for
CANBUS FAILURE: PLATFORM MODULE and ground control boxes. Check
6 6 1000mS AND Platform Mode selected. Retained until power is
wiring along scissor arms lead-
re-cycled.
ing up to Platform.
All Platform functions Prevented. Normal operation from
Ground Mode.
With the Load Sensing System enabled, the control system
failed to receive messages from the Load Sensing System Mod-
Check wiring at the Load Sens-
ule.
CANBUS FAILURE: LOAD SENSING SYSTEM MODULE ing System Module and along
6 6 LSS Module Message – Load Cell Message (0x80) not received
scissor arms leading up to plat-
for 1000mS AND [Machine Setup’s LOAD set to 1=CUTOUT PLT
form.
OR 2=CUTOUT ALL]. Retained until power is re-cycled.
Vehicle assumed to be Overloaded.
A JLG Accessory Module has failed to maintain CANbus com-
munications with the ground module.
ACCESSORY CAN COMMUNICATION LOST The control system received Accessory Message – Control 1 Refer to documentation for the
6 6
from an Accessory Module, but failed to receive another within JLG Accessory to clear difficulty.
1000mS. Retained until power is re-cycled.
No motion interlocks.
Help messages with the 6-7 flash code indicate JLG accessory problems. These faults shall not be latched. Normal operation shall resume if difficulty
is resolved.
A JLG Accessory Module has encountered a fault condition and
reported it via the host control system.
Refer to documentation for the
6 7 ACCESSORY FAULT Accessory Message – Control 1’s Request Accessory Fault flag is
JLG Accessory to clear difficulty.
set to YES. Retained or cleared based on status of flag.
No motion interlocks.
Help messages with the 7-7 flash code indicate motor problems.
The Power Module detected an error in the power wiring (F1 &
F2 Terminals) for the drive motors.
OPEN-CIRCUIT DRIVE MOTOR FIELD WIRING Check power wiring and re-
7 7 The Power Module is reporting a “Field Open Circuit”Fault
cycle power to clear difficulty.
Code (16d). Retained until power is re-cycled.
Drive & Steer Prevented
Help messages with the 8-x flash codes indicate problems with the platform load sensing system. The second digit of the flash code is used to indi-
cated channel.
Cell #1’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #1’s Internal Memory.
8-1 Flash Code This situation indicates that the
LSS CELL #1 ERROR
8 1 LSS Module Message – Status Message (0x81) is reporting sensor is unplugged, or the sen-
“CELL 1 ERROR”AND [Machine Setup’s LOAD is set to 1=CUT- sor is damaged.
OUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.

5-18 31215074
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
Cell #2’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #2’s Internal Memory.
This situation indicates that the
8-2 Flash Code
LSS CELL #2 ERROR sensor is unplugged, or the sen-
8 2 LSS Module Message – Status Message (0x81) is reporting
sor is damaged.
“CELL 2 ERROR”AND [Machine Setup’s LOAD is set to 1=CUT-
OUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
Cell #3’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #3’s Internal Memory.
8-3 Flash Code This situation indicates that the
LSS CELL #3 ERROR
8 3 LSS Module Message – Status Message (0x81) is reporting sensor is unplugged, or the sen-
“CELL 3 ERROR”AND [Machine Setup’s LOAD is set to 1=CUT- sor is damaged.
OUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
Cell #4’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #4’s Internal Memory.
8-4 Flash Code This situation indicates that the
LSS CELL #4 ERROR
8 4 LSS Module Message – Status Message (0x81) is reporting sensor is unplugged, or the sen-
“CELL 4 ERROR”AND [Machine Setup’s LOAD is set to 1=CUT- sor is damaged.
OUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
Help messages with the 9-x flash codes indicate controller (module) problems. The second digit of the flash code provides additional information
about the difficulty.
The Watchdog Timer on Load Sensing System Module’s micro-
processor was triggered by exposure to excessive electrical
noise, or by a hardware difficulty.
LSS WATCHDOG RESET 9-1 Flash Code Re-cycle power to clear diffi-
9 1
LSS Module Message – Status Message (0x81) is reporting culty
“WATCHDOG RST”AND [Machine Setup’s LOAD is set to 1=CUT-
OUT PLT OR 2=CUTOUT ALL]. Retained until power is re-cycled.
No motion interlocks.
Memory used to retain settings on Load Sensing System Mod-
ule has been corrupted and must be reset by verifying all
entries / re-calibrating.
LSS EEPROM ERROR
9-2 Flash Code After resolution, re-cycle power
9 2
LSS Module Message – Status Message (0x81) is reporting to clear difficulty.
“EEPROM ERROR”AND [Machine Setup’s LOAD is set to 1=CUT-
OUT PLT OR 2=CUTOUT ALL]. Retained until power is re-cycled.
Vehicle assumed to be Overloaded

9-3 Flash Code

The Load Sensing System’s Calibration EEPROM for Empty Plat-
form Load is set to Never Set (signature implanted by the In- Calibrate the Load Sensing Sys-
LSS HAS NOT BEEN CALIBRATED
9 3 Circuit Test Fixture) AND [Machine Setup’s LOAD is set to tem using the calibration proce-
1=CUTOUT PLT OR 2=CUTOUT ALL]. Retained until Calibration dure to clear the message.
EEPROM is over-written by a valid calibration.
Vehicle assumed to be Overloaded.

31215074 5-19
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The Excitation Voltage for the Load Sensors < 4.25V.
9-9 Flash Code The sensors may be excessively
LSS Module Message – Status Message (0x81) is reporting loading the Excitation Supply
LSS INTERNAL ERROR – PIN EXCITATION
9 9 “INTERNAL ERROR – PIN EXCITATION < 4.25V”AND [Machine due to wiring damage, or the
Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT ALL]. Load Sensing System Module
Retained until power is re-cycled. may have hardware difficulty.
Vehicle assumed to be Overloaded.
The DRDY Interrupt from the Load Sensing System Module’s A/
D Converter is missing.
9-9 Flash Code
This may indicate Load Sensing
LSS INTERNAL ERROR – DRDY MISSING FROM A/D LSS Module Message – Status Message (0x81) is reporting
9 9 System Module hardware diffi-
“INTERNAL ERROR – DRDY INTERRUPT FROM A/D”AND
culty.
[Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT
ALL]. Retained until power is re-cycled.
Vehicle assumed to be Overloaded.
The Power Module detected an out-of-range or corrupt per-
sonality setting.
9-9 Flash Code Reset control system Personali-
POWER MODULE FAILURE: PERSONALITY RANGE ERROR
9 9 The Power Module is reporting a “Configuration Range”Fault ties to default settings to clear
Code (11d) OR a “Configuration CRC”Fault Code (12d) OR a difficulty.
“Motor Setup”Fault Code (13d). Retained until power is re-
cycled.
The Power Module detected an internal error via self-test.
9-9 Flash Code
The Power Module is reporting a “Two Direction”Fault Code
POWER MODULE FAILURE: INTERNAL ERROR Re-cycle power to clear diffi-
9 9 (4d) OR a “Sequence”Fault Code (5d) OR a “CANbus Input”
culty.
Fault Code (6d) OR a “12V Supply Detection”Fault Code (18d)
OR a “System Monitor Activated”Fault Code (24d). Retained
until power is re-cycled.
The Power Module detected an error in the Power Wiring for
the Drive or Pump. Alternately, the Power Module has failed a
self-test.
POWER MODULE FAILURE: CHECK POWER CIRCUITS OR 9-9 Flash Code Check wiring and motors or
9 9 MOSFET SHORT CIRCUIT The Power Module is reporting an “Armature MOSFET Short replace the Power Module. Re-
Circuit”Fault Code (17d) OR an “Armature MOSFET’s Off”Fault cycle power to clear difficulty.
Code (19d) OR an “Armature MOSFET’s On”Fault Code (20d) OR
an “Armature Pullup MOSFET Short Circuit”Fault Code (21d).
Retained until power is re-cycled.
Refer to Drive Motor Electrical
Evaluation in Section 3.2.
The ground board detected armature, field, or pump current Refer to Pump Motor Electrical
9 9 POWER MODULE FAILURE: SYSTEM MONITOR
while function was not commanded. Evaluation in Section 4.3.
Refer to Power Module Electrical
Evaluation in Section 3.6.
The control system detected an EEPROM failure. Personalities
and Machine Setup settings may be reset to default values.
Check / correct all settings and
EEPROM FAILURE – CHECK ALL SETTINGS 9-9 Flash Code
9 9 re-cycle power to clear diffi-
The control system’s EEPROM checksum indicates corruption.
culty.
Retained until EEPROM settings are corrected and power is re-
cycled.

5-20 31215074
 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Flash Code Listing

Flash
Help Message Cause Possible Resolve
Code
The control system has not been configured for the first time.
Use the JLG Analyzer to adjust all
9-9 Flash Code
FUNCTIONS LOCKED OUT – MACHINE NOT CONFIGURED Machine Setup and Personality
9 9 The control system’s EEPROM flag indicates that the vehicle has
settings and re-cycle power to
not been configured (new control system components).
clear difficulty.
Retained until EEPROM flag is cleared and power is re-cycled.
The control system will not function because the Platform
Module Software Version is not compatible with the rest of the
FUNCTIONS LOCKED OUT – PLATFORM MODULE SOFT- system.
Re-program or replace with a
9 9 WARE VERSION IMPROPER 9-9 Flash Code
Version 1.xx module.
The Platform Module reported a Software Major Version that
was not equal to “1”. The control system may resume operation
once the difficulty has been corrected.
The control system will not function because the Power Mod-
ule Software Version is not compatible with the rest of the sys-
tem.
FUNCTIONS LOCKED OUT – POWER MODULE SOFTWARE
9-9 Flash Code Re-program or replace with a
9 9 VERSION IMPROPER
The Power Module reported a Software Major Version that was Version 1.xx module.
not equal to “1”. The control system may resume operation
once the difficulty has been corrected.

The control system will not function because the LSS Module
Software Version is not compatible with the rest of the system.
FUNCTIONS LOCKED OUT – LSS MODULE SOFTWARE 9-9 Flash Code
Re-program or replace with a
9 9 VERSION IMPROPER Machine Setup’s LOAD=1 or 2 AND the LSS Module reported a
Version 7.xx module.
Software Major Version that was not equal to “7”. The control
system may resume operation once the difficulty has been cor-
rected.

Analyzer Flow Chart

31215074 5-21
 HELP: PRESS CURRENT HELP
ENTER LOGGED: HELP 1 to 16

5-22
MESSAGE

IN-OUT OPEN/CLOSED FOOT SWITCH OPEN/

[ZONE A-B WHEN CLOSED [DISPLAYED DRIVE SEL STEER LT STEER RT TRIGGER
PLATFORM CAPACITY SELECT IS WHEN FOOTSWITCH IS OPEN/CLOSED OPEN/CLOSED OPEN/CLOSED OPEN/CLOSED
1_ZONE A/B] 1=YES]

LIFT SEL JOYSTIC HORN

OPEN/CLOSED 100% TO +100% OPEN/CLOSED

LIFT UP LIFT DN
GROUND OPEN/CLOSED OPEN/CLOSED

SPEED ARM PWM ARM CUR FLD PWM FLD CUR TEMP
TRACTION 0- 100% 0.0- 100.0% xxxA 0.0- 100.0% xxx.xA xx.xC

PUMP PWM PUMP CUR

PUMP 0.0- 100.0% xxx.xA
SECTION 5 - JLG CONTROL SYSTEM

MODE:GROUND LPHP: EXTEND RPHP: EXTEND BATTERY PLT BATT

SYSTEM /PLATFORM /RETRACT /RETRACT xx.xV xx.xV

DIAGNOSTICS TEMPERATURE LOW

TILT +x.x +y.y BRAKES OFF/ON HORN OFF/ON
AMBIENT:XXXC TEMPERATURE
CUTOUT:ACTIVE

PLATFORM STOWED/ PROX SW OPEN/ ANGLE SNSR ZEROED x.xxV CALIB x.xxV
ELEV ELEVATED [HIDDEN CLOSED [HIDDEN xx.xV[HIDDEN V[HIDDEN V[HIDDEN
SENSOR FOR 1230ES] EXCEPT FOR 1230ES] FOR 1230ES] FOR 1230ES] FOR 1230ES]

STEER LEFT STEER RIGHT LIFT UP LIFT DOWN

VALVES OFF/ON OFF/ON OFF/ON 0-100%

AC CONNECTED/
CHARGER NOT CONNECTED

DRIVE xxH
yyM

LIFT xxH
yyM

DATALOG
RENTAL xxH
yyM

ERASE RENTAL? ERASE RENTAL

[DISPLAY FOR YES: ENTER
ACCESS LEVEL NO: ESC
0 & 1]

TO: 1001096495-O
VERSIONS MAF02510O

Figure 5-3. Analyzer Flow Chart (Software Version P1.14) - Sheet 1 of 4

31215074
 LSS HW REVx [Display LSS SW Px.y [Display
when FOOTSWITCH is when FOOTSWITCH is
1=YES or LOAD is 1=YES or LOAD is GM SW Px.y GM HW REV GM SN abcdef
VERSIONS
1=CUTOUT PLT, 1=CUTOUT PLT, x
2=CUTOUT ALL] 2=CUTOUT ALL]

31215074
FROM:
DIAGNOSTICS PM SW px.y PM HW REV x PM SN abcdef PWR SW Px.y

LOAD [Display when OVERLOADED? PLTLOAD +/- PLTGROS +/- CELL 1 +/- CELL 2 +/- CELL 3 +/- CELL 4 +/-
LOAD is 1=CUTOUT NO/YES xxxx KG [Hidden xxxx KG [Hidden xxxx KG [Hidden xxxx KG [Hidden xxxx KG [Hidden xxxx KG [Hidden
PLT, 2=CUTOUT ALL; for 1230ES] for 1230ES] for 1230ES] for 1230ES] for 1230ES] for 1230ES]

TEST GND SW? LIFT DOWN LIFT UP

(Ground Mode OPEN/CLOSED OPEN/CLOSED
only)

TEST PLT SW?

LEFT RIGHT IN/OUT TRIGGER HORN LIFT DRIVE
(Platform Mode
only)

RUN SYSTEM TEST

YES:ENTER,
NO:ESC

TEST OVLD
&ALRM?(Ground OVRLD HORN ALARM
Mode only)
SYSTEM TEST
TEST LEDS BATTERY 1 BATTERY 2 BATTERY 3 BATTERY 4 SYS
&ALRM?(Platform TILT LAMP
(1/4) (1/2) (3/4) (Full) DISTRESS
Mode only)

INDOOR OUTDOOR OVRLD PLAT ALARM

TEST STEER LT STEER RT LIFT UP

VALVES? OPEN/SHORT OPEN/SHORT OPEN/SHORT

TEST PROP
CNTRL?(Platform FWD TO MAX CENTER REV TO MAX
Mode only)

TEST
COMPLETE

ACESS LEVEL CODE xxxx

TO:
MACHINE SETUP 1001096495-O
MAF02520O

5-23
Figure 5-4. Analyzer Flow Chart (Software Version P1.14) - Sheet 2 of 4
SECTION 5 - JLG CONTROL SYSTEM
 FROM:
ACCESS LEVEL

5-24
MODEL NUMBER:
1230ES/(1930ES)/
2030ES/2630ES/
2646ES/3246ES
GROUND ALARM:
CHARGER INTERLOC DRIVE CUTOUT: BATTERY
0=ANSI USA 0=HORN ONLY/ AMB. NOISE
(0=DRIVE ONLY)/ (0=NO/1=YES) (0=FLOODED)/
1=DESCENT ALARM: (0=NO)
1=DRV & LIFT UP 1=AGM
(2=MOTION) /1=YES

GROUND ALARM: LOAD: 0=NOT

1=ANSI CHARGER INTERLOC DRIVE CUTOUT: BATTERY LOW TEMP AMB. NOISE
0=HORN ONLY/ INSTALLED
MACHINE SETUP EXPORT (0=DRIVE ONLY)/ (0=NO/1=YES) (0=FLOODED)/ CUTOUT: ALARM: (0=NO)
1=DESCENT (1=CUTOUT PLT)
1=DRV & LIFT UP 1=AGM (0=NO)/1=YES /1=YES
(2=MOTION) /2=CUTOUT ALL

GROUND ALARM:
CHARGER INTERLOC DRIVE CUTOUT: BATTERY AMB. NOISE
2=CSA 0=HORN ONLY/
(0=DRIVE ONLY)/ (0=NO/1=YES) (0=FLOODED)/ ALARM: (0=NO)
1=DESCENT
1=DRV & LIFT UP 1=AGM /1=YES
(2=MOTION)

CHARGER INTERLOC GROUND ALARM: LOAD: 0=NOT

TILT CUTOUT: DRIVE CUTOUT: BATTERY LOW TEMP AMB. NOISE
MARKET: 3=CE 0=HORN ONLY/ INSTALLED
(0=DRIVE ONLY)/ (0=NO/1=YES) (0=NO/1=YES) (0=FLOODED)/ CUTOUT: ALARM: (0=NO)
1=DESCENT (1=CUTOUT PLT)
SECTION 5 - JLG CONTROL SYSTEM

1=DRV & LIFT UP 1=AGM (0=NO)/1=YES /1=YES

(2=MOTION) /2=CUTOUT ALL

CHARGER INTERLOC LOAD: 0=NOT TILT SELECT AMB. NOISE

DRIVE CUTOUT: BATTERY
4=AUSTRALIA (0=DRIVE ONLY)/ INSTALLED/ 2=3.4 DEGREES/ ALARM: (0=NO)
(0=NO/1=YES) (0=FLOODED)/
1=DRV & LIFT UP (1=CUTOUT PLT) (3=1.5/3.0 DEGREES) /1=YES
1=AGM
(1230ES only)

CHARGER INTERLOC GROUND ALARM: LOAD: 0=NOT

DRIVE CUTOUT: BATTERY FOOTSWITCH: AMB. NOISE
5=JAPAN (0=DRIVE ONLY)/ 0=HORN ONLY/ INSTALLED
(0=NO/1=YES) (0=FLOODED)/ (0=NO/1=YES) ALARM: (0=NO)
1=DRV & LIFT UP 1=DESCENT (1=CUTOUT PLT)
1=AGM /1=YES
(2=MOTION) /2=CUTOUT ALL

CHARGER INTERLOC GROUND ALARM: LOAD: 0=NOT AMB. NOISE

DRIVE CUTOUT: BATTERY FOOTSWITCH:
6=KOREA (0=DRIVE ONLY)/ 0=HORN ONLY/ INSTALLED ALARM: (0=NO)
(0=NO/1=YES) (0=FLOODED)/ (0=NO/1=YES)
1=DRV & LIFT UP 1=DESCENT (1=CUTOUT PLT) /1=YES
1=AGM
(2=MOTION) /2=CUTOUT ALL

LEVEL VEHICLE LEVEL VEHICLE:

TILT TILT = +0.0+0.0/ YES=ENTER
SENSOR SENSOR FAILURE/ NO=ESC
NOT LEVEL

SET STOW ELEV: SET STOW ELEV:

SET STOW
COMPLETE/ YES=ENTER,
ELEV
SENSOR FAILURE NO=ESC

SET MAX ELEV: SET MAX ELEV:

SET MAX
CALIBRATIONS COMPLETE/ YES=ENTER,
ELEV
SENSOR FAILURE NO=ESC

SET 17FT ELEV: SET 17FT ELEV:

SET 17FT COMPLETE/ YES=ENTER
ELEV SENSOR FAILURE NO=ESC

SET 19FT ELEV: SET 19FT ELEV:

SET 19FT COMPLETE/ YES=ENTER
ELEV SENSOR FAILURE NO=ESC

TO:SET 23FT 1001096495-O

ELEV MAF02530O

Figure 5-5. Analyzer Flow Chart (Software Version P1.14) - Sheet 3 of 4

31215074
 FROM:SET
19FT ELEV

31215074
SET 23FT SET 23FT ELEV: SET 23FT ELEV:
ELEV COMPLETE/ YES=ENTER
SENSOR FAILURE NO=ESC

SET 25FT SET 23FT ELEV: SET 25FT ELEV:

ELEV COMPLETE/ YES=ENTER
SENSOR FAILURE NO=ESC

SET ARM GUARD: SET ARM GUARD:

SET ARM COMPLETE/ YES=ENTER
GUARD SENSOR FAILURE NO=ESC

CALIBRATIONS CAL JOYSTICK: CAL JOYSTICK: CAL JOYSTICK: CAL JOYSTICK: CAL JOYSTICK:
JOYSTICK YES=ENTER COMPLETE/ FWD TO MAX CENTER REV TO MAX
NO=ESC CAL FAIL

LOAD COMPLETE LOAD:

LOAD /<MIN CAL/> YES= ENTER,
MAX CAL NO= ESC

DRIVE CUTOUT: DRIVE CUTOUT:

DRIVE COMPLETE/ YES=ENTER
CUROUT SENSOR FAILURE NO=ESC

ACCEL 0.1- DECEL 0.1- MINIMUM MAXIMUM ELEV, MAX

DRIVE 0-100% 0-100%
5.0S 1.0S 0-25%

ACCEL 0.1- DECEL 0.1- UP MIN 0- UP MAX 0- DN MIN 1- DN MAX 1-

LIFT 5.0S 100% 60% 100%
1.0S 100%

STATIC 0- DRIVE 0-
STEER 100% 100%

PERSONALITIES

FWD MIN FWD MAX REV MIN REV MIN

ACCELERATOR 2.20-2.40V 1.00-1.50V 2.60-2.80V 3.50-4.00V

HORN 10- ALRM 10-

GROUND 100%
100%

ACC'Y 0- OVR DBNCE OVR HOLD

LOAD
200KG 0.0-5.0S 0.0-5.0S
1001096495-O
MAF02540O

Figure 5-6. Analyzer Flow Chart (Software Version P1.14) - Sheet 4 of 4

5-25
SECTION 5 - JLG CONTROL SYSTEM
 SECTION 5 - JLG CONTROL SYSTEM

5.9 MACHINE MODEL ADJUSTMENT

Table 5-3. Machine Model Adjustment - Version P1.14

Adjustment Adjustment Range 1930ES 2032ES 2632ES 2646ES 3246ES

DRIVE
ACCEL 0.1 - 5.0 (Sec) 0.7 0.7 0.7 0.7 0.7
DECEL 0.1 - 1.0 (Sec) 0.1 0.1 0.1 0.1 0.1
MINIMUM 0 - 25% 0 0 0 0 0
MAXIMUM 0 -100% 100 100 100 100 100
ELEV. MAX. 0 - 30% 25 25 25 25 25
LIFT
ACCEL 0.1 - 5.0 (Sec) 0.5 0.5 0.5 0.5 0.5
DECEL 0.1 - 1.0 (Sec) 0.1 0.1 0.1 0.1 0.1
UP MIN 0 - 50% 20 20 20 20 20
UP MAX 0 - 100% 100 100 100 100 100
DN MIN 1 - 60% 45 45 45 45 45
DN MAX 1 - 100% 75 75 75 75 75
UP LTC 1 - 100% 50 50 50 50 50
DN LTC 1 - 100% 77 77 77 77 77
DN Max EARM 1 - 100% 70 70 70 70 70
STEER
STATIC 0 - 100% 70 70 70 70 70
DRIVE 0 - 100% 30 30 30 30 30
ACCELERATOR
FWD MIN 2.20 - 2.40 V 2.23 2.23 2.23 2.23 2.23
FWD MAX 1.00 - 1.50 V 1.19 1.19 1.19 1.19 1.19
REV MIN 2.60 - 2.80 V 2.74 2.74 2.74 2.74 2.74
REV MAX 3.50 - 4.00 V 3.78 3.78 3.78 3.78 3.78
GROUND
HORN 10 - 100% 94 94 94 94 94
ALARM 10 - 100% 19 19 19 19 19
LOAD
ACCY 0 - 200 Kg 0 0 0 0 0
OVR DBNCE 0.0 - 5.0 Sec 3.0 3.0 3.0 3.0 3.0
OVR HOLD 0.0 - 5.0 Sec 5.0 5.0 5.0 5.0 5.0
TEMP CUTOUT
CUTOUT SET -30 - 0C -30 -30 -30 -30 -30
OVR DBNCE 0 - 15C 5 5 5 5 5
1001115627-F

NOTE: These settings may change in order to achieve optimal performance on a machine by machine basis.

5-26 31215074
 SECTION 5 - JLG CONTROL SYSTEM

5.10 MACHINE CONFIGURATION PROGRAMMING INFORMATION

NOTE: When configuring an ES scissors machine, the machine configuration must be completed before any personality set-
tings can be changed. Changing the personality settings first and then changing the model number of the machine con-
figuration will cause the personality settings to return to default.
Shaded entries are not available for the selected Market.

Table 5-4. Machine Configuration Programming Information - Version P1.14

Configuration * Market Default Setting
Setting Description
Digit 0 1 2 3 4 5 6
1 1930ES
2 2032ES
1 (Set to your applicable ES Model
3 2632ES
(Model #) 1 through 5)
4 2646ES
5 3246ES
0 ANSI USA
1 ANSI EXPORT
2 CSA
2 0 - (ANSI USA)
3 CE
(Market ) (Set to your applicable market)
4 AUSTRALIA
5 JAPAN
6 KOREA
3 0 NO - Drive and lift up not prevented while tilted (Ground and Platform Mode).
1 1 1 1 1 1 1
(Tilt Cutout) 1 YES - Drive and lift up prevented while tilted (Ground and Platform Mode).
4 0 NO - Drive and lift up not prevented while elevated.
0
(Drive Cutout) 1 YES - Drive and lift up prevented while elevated.
0 DRIVE ONLY - Drive motion prevented while vehicle is charging.
5
1 DRIVE AND LIFT UP - Drive and lift up motions are prevented while vehicle is charging. 0 0 0 0 0 0 0
(Charger Interlock)
Required for CE.
0 NOT INSTALLED - Vehicle alarm will function for Arm Guard (if enabled), Overload (if LSS
enabled), and as a horn.
6 1 DESCENT - Vehicle alarm will function for Arm Guard (if enabled), Overload (if LSS
2 2 2 0 2 2 2
(Ground Alarm) enabled, as a horn, and during Lift Down motion.
2 MOTION - Vehicle alarm will function for Arm Guard (if enabled), Overload (if LSS
enabled, as a horn, and during Drive and Lift motions.
0 NOT INSTALLED - Load Sensing System (LSS) is not fitted to the vehicle.
7 1 CUTOUT PLT - Load Sensing System (LSS) is fitted, and Platform Controls are prevented in
(LSS - the event of an Overload. Ground Controls remain functional. This is the default setting
1 1 1 2 1 1 1
Load Sensing for CE machines.
System) 2 CUTOUT ALL - Load Sensing System (LSS) is fitted. Platform and Ground Controls are pre-
vented in the event of an overload.
8 0 FLOODED - Batteries are conventional lead-acid type.
0
(Battery) 1 AGM - Batteries are absorbed glass mat type.
9 0 NO - Vehicle is not fitted with a footswitch
0 0 0 0 0 1 1
(Footswitch) 1 YES - Vehicle is fitted with a footswitch
10 0 NO – Vehicle is not fitted with a white noise alarm.
0 0 0 0 1 0 0
(Wht. Noise Alarm) 1 YES – Vehicle is fitted with a white noise alarm.
11 0 NO – Vehicle is not fitted with low temperature cutout.
0 0 0 0 0 0 0
(Low Temp Cutout) 1 YES – Vehicle is fitted with low temperature cutout.
12 0 NO – Vehicle is not configured for the Beacon Option.
(Beacon) 1 YES – Vehicle is configured for the Beacon Option. 0 0 0 0 0 0 0
2 NO RELAY – Vehicle does not have a beacon relay and is configured to work PRE-EN280.
13 0 NO – Vehicle is not configured with PHP Alarm when Pothole bar is blocked.
0 0 0 0 0 0 0
(PHP Alarm) 1 YES - Vehicle is configured with PHP Alarm when Pothole bar is blocked.
1001115626-H

31215074 5-27
 SECTION 5 - JLG CONTROL SYSTEM

5-28 31215074
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

SECTION 6. DIAGNOSTIC TROUBLE CODES

6.1 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 MDI and SEVCON Power Module-(ground
board software version P1.13 or higher) or ZAPI Power Module-(ground board software version P1.0 or higher). For
more information on the MDI or any sensors or indicators, refer to the appropriate section for the machine area. Many
of the checks below require configuring and using a multimeter. Refer to Section 7: General Electrical Information &
Schematics for multimeter basics. DTCs are sorted in groups by the first two digits, which is also the system distress
lamp flash code. To troubleshoot multiple DTCs, start with the DTC with the higher first two digits. The machine is
powered by four 6 Volt batteries in series, providing a nominal 24 Volts to the control system. Some procedures
below refer to this nominal voltage (VMN) as 24V. Actual voltage measurements may differ based on the charge of
the batteries. If a correction is made during a check, conclude the check by cycling the machine power, using
the emergency stop switch. It may also be helpful to run a system test, ANALYZER -> SYSTEM TEST for intermittent
or difficult problems.

6.2 DTC INDEX

Error
Error (Displayed on MDI) .......................................................................................................................................................................................................6-4
0-0
001 EVERYTHING OK ...............................................................................................................................................................................................................6-4
002 GROUND MODE OK ........................................................................................................................................................................................................6-4
003 ALARM SOUNDING - TILTED & ABOVE ELEVATION ......................................................................................................................................6-4
004 DRIVING AT CUTBACK - ABOVE ELEVATION .....................................................................................................................................................6-4
005 DRIVE & LIFT UP PREVENTED - TILTED & ELEVATED .....................................................................................................................................6-5
006 LIFT UP PREVENTED - MAX HEIGHT ZONE A ....................................................................................................................................................6-5
007 DRIVING AT CUTBACK - POTHOLE STILL ENGAGED .....................................................................................................................................6-5
008 FUNCTIONS LOCKED OUT - SYSTEM POWERED DOWN ............................................................................................................................6-5
009 DRIVE PREVENTED - ELEVATED ABOVE DRIVE CUTOUT HEIGHT ..........................................................................................................6-6
2-1
211 POWER CYCLE ....................................................................................................................................................................................................................6-6
212 KEYSWITCH FAULTY .......................................................................................................................................................................................................6-6
2-2
221 FUNCTION PROBLEM - HORN PERMANENTLY SELECTED .........................................................................................................................6-6
222 FUNCTION PROBLEM - INDOOR / OUTDOOR PERMANENTLY SELECTED ........................................................................................6-6
223 FUNCTION PROBLEM - DRIVE & LIFT ACTIVE TOGETHER ..........................................................................................................................6-6
224 FUNCTION PROBLEM - STEER LEFT PERMANENTLY SELECTED .............................................................................................................6-7
225 FUNCTION PROBLEM - STEER RIGHT PERMANENTLY SELECTED ..........................................................................................................6-7
226 ACCELERATOR FAULTY - WIPER OUT OF RANGE ...........................................................................................................................................6-7
227 STEER SWITCHES FAULTY ...........................................................................................................................................................................................6-7
228 FUNCTION LOCKED OUT - ACCELERATOR NOT CENTERED .....................................................................................................................6-7
229 FUNCTION PROBLEM - TRIGGER PERMANENTLY CLOSED .......................................................................................................................6-7
2210 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL .....................................................................................................................................6-8
2-3
231 FUNCTION PROBLEM - LIFT PERMANENTLY SELECTED .............................................................................................................................6-8
232 GROUND LIFT UP / DOWN ACTIVE TOGETHER ...............................................................................................................................................6-8
233 FUNCTION PROBLEM - BRAKE RELEASE PERMANENTLY SELECTED ...................................................................................................6-8
2-5
251 ELEV ANGLE SENSOR FAULTY - VOLTAGE OUT OF RANGE ......................................................................................................................6-9
252 ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED .....................................................................................................................................6-9
253 DRIVE PREVENTED - CHARGER CONNECTED ...................................................................................................................................................6-9
254 DRIVE & LIFT UP PREVENTED - CHARGER CONNECTED .............................................................................................................................6-9
255 PLATFORM OVERLOADED ..........................................................................................................................................................................................6-9
256 DRIVE PREVENTED - POTHOLE NOT ENGAGED ........................................................................................................................................... 6-10
257 ELEV PROX PERMANENTLY CLOSED - CHECK PROX AND ANGLE ADJUSTMENT ..................................................................... 6-10
258 DRIVE & LIFT PREVENTED - BRAKES ELECTRICALLY RELEASED FOR TOWING ............................................................................ 6-10
259 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS ............................................................................................................. 6-10
2510 DRIVE PREVENTED - BRAKES NOT RELEASING ........................................................................................................................................... 6-10

31215074 6-1
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

2511 ELEV ANGLE SENSOR FAULTY - NOT MOUNTED ......................................................................................................................................6-10

2512 ELEV ANGLE SENSOR NOT DETECTING CHANGE .....................................................................................................................................6-10
3-1
311 OPEN CIRCUIT LINE CONTACTOR ........................................................................................................................................................................6-11
312 CONTACTOR DRIVER PERMANENTLY OFF ......................................................................................................................................................6-11
3-2
321 LINE CONTACTOR MISWIRED ON OR WELDED ............................................................................................................................................6-11
322 CONTACTOR DRIVER PERMANENTLY ON ........................................................................................................................................................6-11
326 AUXILIARY RELAY SHORT TO BATTERY ............................................................................................................................................................6-11
3-3
331 BRAKE SHORT TO BATTERY .....................................................................................................................................................................................6-12
332 BRAKE OPEN CIRCUIT ..................................................................................................................................................................................................6-12
333 LIFT UP SHORT TO BATTERY ...................................................................................................................................................................................6-12
334 LIFT UP OPEN CIRCUIT ................................................................................................................................................................................................6-12
335 LIFT DN SHORT TO BATTERY ...................................................................................................................................................................................6-12
336 LIFT DN OPEN CIRCUIT ...............................................................................................................................................................................................6-12
337 STEER LEFT SHORT TO BATTERY ...........................................................................................................................................................................6-12
338 STEER LEFT OPEN CIRCUIT .......................................................................................................................................................................................6-12
339 STEER RIGHT SHORT TO BATTERY .......................................................................................................................................................................6-13
3310 STEER RIGHT OPEN CIRCUIT .................................................................................................................................................................................6-13
3311 GROUND ALARM SHORT TO BATTERY ...........................................................................................................................................................6-13
3312 LEFT BRAKE SHORT TO BATTERY .......................................................................................................................................................................6-13
3313 RIGHT BRAKE SHORT TO BATTERY ....................................................................................................................................................................6-13
3314 LEFT BRAKE OPEN CIRCUIT ...................................................................................................................................................................................6-13
3315 RIGHT BRAKE OPEN CIRCUIT ................................................................................................................................................................................6-13
4-2
421 POWER MODULE TOO HOT - PLEASE WAIT ...................................................................................................................................................6-15
422 DRIVING AT CUTBACK - POWER MODULE CURRENT LIMIT ...................................................................................................................6-15
423 LIFT UP AT CUTBACK - POWER MODULE CURRENT LIMIT .....................................................................................................................6-15
4-4
441 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN .............................................................................................................................6-15
442 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN ............................................................................................................................6-15
443 LSS BATTERY VOLTAGE TOO HIGH ......................................................................................................................................................................6-15
444 LSS BATTERY VOLTAGE TOO LOW .......................................................................................................................................................................6-15
6-6
661 CANBUS FAILURE - POWER MODULE ................................................................................................................................................................6-16
662 CANBUS FAILURE - PLATFORM MODULE ........................................................................................................................................................6-17
663 CANBUS FAILURE - LOAD SENSING SYSTEM MODULE ............................................................................................................................6-18
664 CANBUS FAILURE - ACCESSORY MODULE ......................................................................................................................................................6-18
6-7
671 ACCESSORY FAULT ......................................................................................................................................................................................................6-18
8-1
811 TILT SENSOR NOT CALIBRATED ............................................................................................................................................................................6-20
812 NO DATA FROM TILT SENSOR - NOT CONNECTED OR FAULTY ..........................................................................................................6-20
8-2
821 LSS CELL #1 ERROR .......................................................................................................................................................................................................6-20
822 LSS CELL #2 ERROR .......................................................................................................................................................................................................6-20
823 LSS CELL #3 ERROR .......................................................................................................................................................................................................6-20
824 LSS CELL #4 ERROR .......................................................................................................................................................................................................6-21
825 LSS HAS NOT BEEN CALIBRATED .........................................................................................................................................................................6-21
9-9
991 LSS WATCHDOG RESET ..............................................................................................................................................................................................6-21
992 LSS EEPROM ERROR .....................................................................................................................................................................................................6-21
993 LSS INTERNAL ERROR - PIN EXCITATION ..........................................................................................................................................................6-21
994 LSS INTERNAL ERROR - DRDY MISSING FROM A/D ....................................................................................................................................6-21
995 POWER MODULE FAILURE - PERSONALITY RANGE ERROR ...................................................................................................................6-21
996 POWER MODULE FAILURE - INTERNAL ERROR .............................................................................................................................................6-21
997 POWER MODULE FAILURE - CHECK POWER CIRCUITS OR MOSFET SHORT CIRCUIT ..............................................................6-21
998 EEPROM FAILURE - CHECK ALL SETTINGS .......................................................................................................................................................6-21
999 FUNCTION LOCKED OUT - POWER MODULE SOFTWARE VERSION IMPROPER .........................................................................6-21
9910 FUNCTION LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER ..............................................................6-21

6-2 31215074
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

9911 FUNCTION LOCKED OUT - LSS MODULE SOFTWARE VERSION IMPROPER ............................................................................... 6-22
9912 POWER MODULE FAILURE - SYSTEM MONITOR ....................................................................................................................................... 6-22
9924 FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED ................................................................................................................. 6-22

31215074 6-3
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

6.3 DTC CHECK TABLES

0-0 Help Comments
DTC FAULT MESSAGE DESCRIPTION CHECK
ERROR Error (Displayed on MDI) The MDI is powered, but cannot • Check the MDI connector.
communicate with the control • Check the diagnostic connector.
system. • Check continuity between MDI connector socket 6
and ground board connector socket J1-4.
• Check continuity between MDI connector socket 4
and ground board connector socket J1-3.
• Check that the ground board software version is P1.13
or higher.
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 - Control system senses that the • Check that the machine is tilted. If so, lower the plat-
TILTED & ABOVE ELEVA- platform is elevated and the form and reposition the machine to a level surface.
TION vehicle is tilted, and the machine • Fully stow the platform.
not configured to cutout. • The tilt sensor is part of the ground control box. Check
that the ground control box is secured to the
machine.
• Check that the pothole protection switches are
securely mounted.
• Check that the elevation angle sensor is securely
mounted.
• Check the ANALYZER -> MACHINE SETUP -> MARKET
configuration.
• If MARKET is set to CE, ensure ANALYZER -> MACHINE
SETUP -> TILT CUTOUT parameter is set as desired.
• Backprobing ground board J1-18 should show about
0 volts.
• Backprobing ground board J1-10 should show about
0 volts.
• Check pothole protection switch adjustment.
• Calibrate the elevation sensor, see Section 5.5.
• Calibrate the tilt sensor, see Section 5.2.
004 DRIVING AT CUTBACK - The platform is elevated and the • Fully stow the platform.
ABOVE ELEVATION machine is driving. • Check that the elevation angle sensor is securely
mounted.
• Check that the pothole protection switches are
securely mounted.
• Check the lift/drive switch.
• Backprobing ground board J1-18 should show about
0 volts.
• Backprobing ground board J1-10 should show about
0 volts.
• Check function of elevation angle sensor. ANALYZER -
> DIAGNOSTICS -> ELEV SENSOR -> ZEROED should
be about 0V when stowed and about 0.15V at cut-
back.

6-4 31215074
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

0-0 Help Comments

DTC FAULT MESSAGE DESCRIPTION CHECK
005 DRIVE & LIFT UP PRE- Driving is not possible since the • Check that the machine is tilted. If so, lower the plat-
VENTED - TILTED & ELE- platform is elevated and the form and reposition the machine to a level surface.
VATED chassis is not level. • Fully stow the platform.
• The tilt sensor is part of the ground control box. Check
that the ground control box is secured to the
machine.
• Check that the pothole protection switches are
securely mounted.
• Check that the elevation angle sensor is securely
mounted.
• Check the ANALYZER -> MACHINE SETUP -> MARKET
configuration.
• If MARKET is set to CE, ensure ANALYZER -> MACHINE
SETUP -> TILT CUTOUT parameter is set as desired.
• Check pothole protection switch adjustment.
• Backprobing ground board J1-18 should show about
0 volts.
• Backprobing ground board J1-10 should show about
0 volts.
• Calibrate the elevation sensor, see Section 5.5.
• Calibrate the tilt sensor, see Section 5.2.
006 LIFT UP PREVENTED - The vehicle has reached the • Check that the zone is set appropriately for the plat-
MAX HEIGHT ZONE A maximum height and further lift form load.
up motion is not possible. Appli- • Check that the platform height is at the rated maxi-
cable to 2632ES or 3246ES. mum height specification (20’ for 2632 or 26’ for the
3246).
• Check that the elevation angle sensor is securely
mounted.
• If there are any elevation sensor faults (DTC 251, 252,
2511, or 2512), troubleshoot those first.
• Check that ANALYZER -> MACHINE SETUP -> MODEL
setting is correct.
• Check that ANALYZER -> MACHINE SETUP -> MARKET
setting is correct.
• Check ANALYZER -> DIAGNOSTICS -> ELEV SENSOR ->
ZEROED is about 1.53V for the 3246 or about 1.22V for
the 2632 when at full height. If not, repair or replace
the elevation angle sensor.
007 DRIVING AT CUTBACK - While stowed, drive speed is • Check for obstructions around the pot-hole protec-
POTHOLE STILL reduced since the control sys- tion mechanisms.
ENGAGED tem detected that the pot-hole • Check that the PHP switches are securely mounted.
protection mechanism failed to • Check PHP switches wiring from the ground board
retract. and for proper operation. The left PHP input (24V) is
from J1-9 and its output (24V when deployed) is to J1-
10. The right PHP input (24V) is from J1-17 and its out-
put (24V when deployed) is to J1-18.
008 FUNCTIONS LOCKED After 2 hours without activity, • Normal operation should resume after a power cycle.
OUT - SYSTEM POW- the control system enters a low- • Check batteries charge, condition, etc.
ERED DOWN power state to preserve battery
charge.

31215074 6-5
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

0-0 Help Comments

DTC FAULT MESSAGE DESCRIPTION CHECK
009 DRIVE PREVENTED - ELE- The platform is elevated above • Check that the elevation angle sensor is securely
VATED ABOVE DRIVE the calibrated cutout height. mounted.
CUTOUT HEIGHT • Check the ANALYZER -> MACHINE SETUP -> MARKET
configuration.
• If MARKET is set to Japan, ensure ANALYZER ->
MACHINE SETUP -> DRIVE CUTOUT parameter is set as
desired.

2-1 Power-Up
DTC FAULT MESSAGE DESCRIPTION CHECK
211 POWER CYCLE This help message is issued at Normal operation. No check necessary.
each power cycle. Displays on
the analyzer only.
212 KEYSWITCH FAULTY Both platform and ground • Check key switch function.
modes are selected simultane- • Backprobe J2-3 with the keyswitch in the ground
ously. Defaults to ground mode. position. Voltage should be under 6V. Otherwise, key-
switch or wiring faulty.
• Backprobe J2-4 with the keyswitch in the platform
position. Voltage should be under 6V. Otherwise, key-
switch or wiring faulty.
• Check key switch wiring to ground board J2-3 and J2-
4 and to emergency stop switch.
• Replace ground board.

2-2 Platform Controls

DTC FAULT MESSAGE DESCRIPTION CHECK
221 FUNCTION PROBLEM - The horn switch was closed • Check if the horn switch is damaged, obstructed or
HORN PERMANENTLY during power-up in platform jammed.
SELECTED mode. • Disconnect the horn switch ribbon cable on the plat-
form board. If DTC still present, replace the platform
board. If DTC 221 is no longer present, replace the
horn switch or platform board.
222 FUNCTION PROBLEM - The indoor / outdoor (zone A / • Check if the indoor/outdoor (zone A / zone B) capacity
INDOOR / OUTDOOR zone B) switch was closed switch is damaged, obstructed or jammed.
PERMANENTLY during power-up in platform • Replace platform board.
SELECTED mode.
223 FUNCTION PROBLEM - The drive and lift inputs are • Check drive/lift switch for visible damage.
DRIVE & LIFT ACTIVE closed simultaneously in plat- • Check switch continuity. There should only be conti-
TOGETHER form mode. nuity from the center post to one of the outer posts at
a time. Otherwise, replace the switch.
• Check drive/lift switch signal and wiring to the plat-
form board. Its input (0V) is from platform board ter-
minal J1-11. "Lift" selection output (0V when selected)
is to platform board terminal J1-9. "Drive" selection
output (0V when closed) is to platform board terminal
J1-10.
• Replace platform board.

6-6 31215074
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

2-2 Platform Controls

DTC FAULT MESSAGE DESCRIPTION CHECK
224 FUNCTION PROBLEM - The steer left switch was closed • Check if the steer left switch is obstructed or jammed.
STEER LEFT PERMA- during power-up in platform • Check steer left switch and its wiring. The steer left
NENTLY SELECTED mode. switch input (24V) is from platform board terminal J1-
1, and its output (24V when closed) is to platform
board terminal J1-15.
• Replace platform board.
225 FUNCTION PROBLEM - The steer right switch was • Check if the steer right switch is obstructed or
STEER RIGHT PERMA- closed during power-up in plat- jammed.
NENTLY SELECTED form mode. • Check steer right switch and its wiring to the platform
board. The steer right switch input (24V) is from plat-
form board terminal J1-1, and its output (24V when
closed) is to platform board terminal J1-16.
• Replace platform board.
226 ACCELERATOR FAULTY - The joystick signal is outside the • Center joystick and check to see if a power cycle will
WIPER OUT OF RANGE acceptable range of 0.50V - 4.5V, clear DTC.
or is unstable. • Check the joystick signal and its wiring. The joystick
input (5V) is from the platform board terminal J1-5, its
output (2.5V with joystick at center) to the platform
board terminal J1-6, and its ground (0V) is to the plat-
form board terminal J1-7. Observe output signal while
slowly operating joystick.
• Replace platform board.
227 STEER SWITCHES The steer left and steer right • Check if the steer switches are damaged, obstructed
FAULTY inputs were closed simultane- or jammed.
ously. • Check the steer switch signals and wiring to the plat-
form board. The steer switch input (24V) is from plat-
form board terminal J1-1, outputs (24V when closed)
are to platform board terminals J1-15 and J1-16 (left
and right).
• Replace platform board.
228 FUNCTION LOCKED The joystick was not centered at • Release joystick and allow to center.
OUT - ACCELERATOR power-up. • Check if the joystick is obstructed or jammed.
NOT CENTERED • Check the joystick signal and its wiring. The joystick
input (5V) is from the platform board terminal J1-5, its
output (2.5V with joystick at center) to the platform
board terminal J1-6, and its ground (0V) is to the plat-
form board terminal J1-7. Observe output signal while
slowly operating joystick.
• Replace platform board.
229 FUNCTION PROBLEM - The trigger switch was closed • Check if the trigger switch is obstructed or jammed.
TRIGGER PERMA- during power-up in platform • Check the trigger switch signal and wiring to the plat-
NENTLY CLOSED mode. form 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.
• Replace platform board.
(Japanese or Korean Specifica- • Release one switch.
tion Only) • Repair the switches/wiring to clear the difficulty.
The footswitch in the platform
and trigger switch were closed
during power-up in platform
mode.

31215074 6-7
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

2-2 Platform Controls

DTC FAULT MESSAGE DESCRIPTION CHECK
2210 TRIGGER CLOSED TOO The trigger switch was closed for • Check if the trigger switch is obstructed or jammed.
LONG WHILE IN NEU- more than five seconds while • Check the trigger switch signal and wiring to the plat-
TRAL the joystick was centered. form 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.
• Replace platform board.
2211 FOOTSWITCH CLOSED (Japanese or Korean Specifica- • Release either switch.
TOO LONG WHILE IN tion Only) • Repair switch/wiring to clear the difficulty.
NEUTRAL The footswitch in the platform
and trigger switch were closed
simultaneously for more than
seven seconds while the joystick
was centered.
2232 FUNCTION PROBLEM - The drive and lift inputs are both • Check if either function is active, if Yes;
DRIVE & LIFT BOTH de-energized in Platform Mode. • Repair the wiring or switch to clear the message.
OPEN • ZAPI - HEALTH (Status LED) - ON

2-3 Ground Controls

DTC FAULT MESSAGE DESCRIPTION CHECK
231 FUNCTION PROBLEM - The ground control box lift • Check if the lift switch is obstructed or jammed.
LIFT PERMANENTLY switch was closed up or down, • Check the lift switch signal and wiring to the ground
SELECTED during power-up in ground board. The lift switch input (24V) is from ground
mode. board terminal J2-4, and its outputs (24V when
closed) are to ground board terminals J2-6, J2-7 (up
and down).
• Replace ground board.
232 GROUND LIFT UP / The lift up / down inputs are • Check if the lift switch is obstructed or jammed.
DOWN ACTIVE closed simultaneously. • Check the lift switch signal and wiring to the ground
TOGETHER board. The lift switch input (24V) is from ground
board terminal J2-4, and its outputs (24V when
closed) are to ground board terminals J2-6 (up), J2-7
(down).
• Replace ground board.
233 FUNCTION PROBLEM - The manual brake release switch • Check if the brake release switch is obstructed or
BRAKE RELEASE PERMA- was closed during power-up. jammed.
NENTLY SELECTED • Check the brake release switch signal and wiring to
the ground board. The brake release switch input
(24V) is from ground board terminal J1-19, and its out-
put (24V when closed) is to ground board terminal J1-
20.
• If the brakes are released, the machine can be pushed
or moved without drive motor power.
• Replace ground board.

6-8 31215074
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

2-5 Function Prevented

DTC FAULT MESSAGE DESCRIPTION CHECK
251 ELEV ANGLE SENSOR The elevation angle sensor • Check that the platform elevation sensor is securely
FAULTY - VOLTAGE OUT input voltage is outside the mounted and undamaged.
OF RANGE acceptable range of 0.10V - • Check voltage as displayed on ANALYZER -> DIAG-
4.50V. NOSTICS -> ELEV SENSOR -> ANGLE SNSR. Backprobe
ground board J1-15. If this voltage disagrees with the
ANGLE SNSR voltage, replace the ground board.
• Backprobe the elevation angle sensor connector. Ter-
minal A should be 4.7V, terminal C should be 0V.
• Check the elevation angle sensor signal and wiring to
the ground board. The elevation angle sensor input is
from ground board terminal J1-14 (4.7V), its output
(0.1 - 1.2V when stowed) is to ground board terminal
J1-15, and its ground is to ground board terminal J1-
16.
• Replace the ground board.
252 ELEV ANGLE SENSOR The elevation angle sensor has • Calibrate the elevation angle sensor to clear fault. See
HAS NOT BEEN CALI- not been calibrated. Section 5.5.
BRATED
253 DRIVE PREVENTED - Driving is not possible while the • Check if the charger is connected to off board power
CHARGER CONNECTED vehicle is charging. source and disconnect if desired.
• Check ANALYZER -> MACHINE SETUP -> CHARGER
INTERLOC is set as desired.
• Check that charger's red (positive) battery wire con-
nector terminal is receiving power (24V) from batter-
ies.
• Check signal from charger interlock connector termi-
nal 2 to ground board terminal J1-29, where 0VDC
indicates charging in process.
254 DRIVE & LIFT UP PRE- Drive or lift is not possible while • Check if the charger is connected to off board power
VENTED - CHARGER the vehicle is charging AND is source and disconnect if desired.
CONNECTED configured to prevent all • Check ANALYZER -> MACHINE SETUP -> CHARGER
motion. INTERLOC is set as desired. (Must be in ACCESS LEVEL
1 to change.)
• Check that charger's red (positive) battery wire con-
nector terminal is receiving power (24V) from batter-
ies.
• Check signal from charger interlock connector termi-
nal 2 to ground board terminal J1-29, where 0VDC
indicates charging in process.
255 PLATFORM OVER- The load sensing system mea- • Remove excess weight from the platform.
LOADED sured platform load is excessive. • Check that the platform is not caught on something,
preventing up or down movement.
• If any CAN bus faults are active, troubleshoot those
first.
• Refer to Section 2.3: Troubleshooting in the LSS man-
ual, 3124288.

31215074 6-9
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

2-5 Function Prevented

DTC FAULT MESSAGE DESCRIPTION CHECK
256 DRIVE PREVENTED - Driving is not possible while ele- • Check for obstructions or mechanical problems
POTHOLE NOT vated since the pot-hole protec- around the pot-hole protection mechanisms.
ENGAGED tion system failed to deploy. • Check that the PHP switches are securely mounted.
• Adjust pot-hole protection switches.
• Check the pothole protection switches signal and wir-
ing to the ground board. The left pot-hole protection
switch input (24V) is from ground board terminal J1-9,
and its output (24V when deployed) is to ground
board terminal J1-10. The right pot-hole protection
switch input (24V) is from ground board terminal J1-
17, and its output (24V when deployed) is to ground
board terminal J1-18.
257 ELEV PROX PERMA- The elevation proximity switch • Verify that an elevation proximity switch is present on
NENTLY CLOSED - shows the platform to be the machine. If not, ensure ANALYZER -> MACHINE
CHECK PROX AND stowed, while the elevation SETUP -> ELEV PROX is set to NOT INSTALLED. If the
ANGLE ADJUSTMENT angle sensor shows the platform switch is present, set ELEV PROX to INSTALLED and
to be raised. The elevation prox- check switch continuity. The switch should close
imity switch is only found on cer- when placed in close proximity to ferrous metal.
tain older lifts. This switch is not
used on current machines so
this DTC should not occur.
258 DRIVE & LIFT PRE- Manual brake release mode is • Push manual brake release switch again or cycle
VENTED - BRAKES ELEC- activated with the switch in the power to clear manual brake release mode.
TRICALLY RELEASED battery box near the ground • Check if the brake release switch is obstructed or
FOR TOWING control box. Drive or lift is not jammed.
possible. • Check the brake release switch signal and wiring to
the ground board. The switch input (24V) is from
ground board terminal J1-19, and its output (24V
when closed) is to ground board terminal J1-20.
• Replace ground board.
259 MODEL CHANGED - The model selection has been • Check ANALYZER -> MACHINE SETUP -> MODEL NUM-
HYDRAULICS SUS- changed. BER.
PENDED - CYCLE EMS • Replace ground board.
2510 DRIVE PREVENTED - While driving on a level surface, • Ensure vehicle is not stuck on something preventing
BRAKES NOT RELEASING armature current was > 150A for movement.
five seconds. Brakes assumed to • Check / repair drive motor wiring, brakes or mechani-
not be releasing properly. cal issues.
2511 ELEV ANGLE SENSOR The input voltage from the ele- • Check that the elevation angle sensor is securely
FAULTY - NOT MOUNTED vation angle sensor indicates mounted.
the elevation angle sensor is not • Check that the elevation angle sensor mechanisms
mounted. are intact.
• Replace elevation angle sensor.
2512 ELEV ANGLE SENSOR The input voltage from the ele- • Check that the elevation angle sensor is securely
NOT DETECTING vation angle sensor did not mounted.
CHANGE change while vehicle was lifting • Check elevation angle sensor is not jammed or
up. obstructed.
• If there are any other elevation angle sensor, joystick,
or lift up faults, troubleshoot them before continuing.
• Replace elevation angle sensor.

6-10 31215074
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

3-1 Line Contactor Open Circuit

DTC FAULT MESSAGE DESCRIPTION CHECK
311 OPEN CIRCUIT LINE The power modules line contac- • Check contactor main contact wiring to battery (+)
CONTACTOR tor did not close when ener- terminal and power controller terminal B+.
gized. Drive, steer and lift up • Contactor solenoid resistance should measure about
prevented. 52 Ohms.
• Check contactor solenoid wiring to power module 12
position connector terminal 8 and ground board ter-
minal J1-19.
• Check that power module 12 position connector ter-
minal 8 goes from 24V to near 0V while contactor
should be closing. If this happens replace contactor.
• Replace the line contactor.
312 CONTACTOR DRIVER The power modules line contac- • Check continuity between contactor connector pin 1
PERMANENTLY OFF tor drive circuitry failed to ener- and ground board socket J1-19.
gize when requested. Drive, • Contactor solenoid resistance should measure about
steer and lift up prevented. 52 Ohms.
• Check continuity between contactor connector pin 2
and power module connector socket 8.
• Replace power module.
314 AUXILIARY RELAY - The auxiliary relay did not close • Check the auxiliary relay coil and associated wiring to
OPEN CIRCUIT when energized. J1-13 and J1-32.
• No voltage on J1-28.
• HEALTH (Status LED) - ON

3-2 Line Contactor Short Circuit

DTC FAULT MESSAGE DESCRIPTION CHECK
321 LINE CONTACTOR MIS- Battery voltage was present at • Check wiring of contactor.
WIRED ON OR WELDED the power module B+ terminal • Check resistance between the studs of the contactor
at power up. Drive, steer and lift while disconnected from the machine.
up prevented. • Check contactor main contact wiring to battery (+)
terminal and power module terminal B+.
• 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.
• Measure voltage between power model B+ and B- ter-
minals. If 24V is present, replace line contactor.
• Replace power module.
322 CONTACTOR DRIVER The power modules line contac- • Check continuity between contactor connector pin 1
PERMANENTLY ON tor drive circuitry failed to de- and ground board socket J1-19.
energize when requested. Drive, • Check continuity between contactor connector pin 2
steer and lift up prevented. and power module 12 position connector terminal 8.
• Replace power module.
326 AUXILIARY RELAY The System Module did not acti- • Check contacts and coils of auxiliary relay.
SHORT TO BATTERY vate the Negative Main Contac- • Check if no motion interlocks
tor driver, but battery voltage • Check voltage on J1-28.
was measured on the J1-28 of • HEALTH (Status LED) - ON
the controller.

31215074 6-11
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

3-3 Ground Output Driver

DTC FAULT MESSAGE DESCRIPTION CHECK
331 BRAKE SHORT TO BAT- The ground board detected • Ensure ANALYZER -> MACHINE SETUP -> ELEV PROX is
TERY voltage while the brake sole- set to NOT INSTALLED.
noid was commanded off.
332 BRAKE OPEN CIRCUIT The ground board did not • Ensure ANALYZER -> MACHINE SETUP -> ELEV PROX is
detect current flow to the brake set to NOT INSTALLED.
solenoid during normal opera-
tion.
333 LIFT UP SHORT TO BAT- The ground board detected • Check for continuity through this circuit. The lift up
TERY voltage while the lift up sole- solenoid resistance should measure about 30 Ohms.
noid was commanded off at The lift up solenoid is powered with 24V from ground
power up. board J1-25, and its ground is to ground board J1-30,
37.
• Inspect the wiring for physical damage.
• Replace ground board.
334 LIFT UP OPEN CIRCUIT The ground board did not • Check for continuity through this circuit. The lift up
detect current flow to the lift up solenoid resistance should measure about 30 Ohms.
solenoid during power up. The lift up solenoid is powered with 24V from ground
board J1-25, and its ground is to ground board J1-30,
37.
• Inspect the wiring for physical damage.
• Replace ground board.
335 LIFT DN SHORT TO BAT- The ground board detected • Check ANALYZER -> MACHINE SETUP -> ELEV PROX is
TERY voltage while the lift down sole- set to NOT INSTALLED
noid was commanded off. • Check for continuity through this circuit. The lift down
solenoid resistance should measure about 20 Ohms.
The lift down solenoid is powered (PWM) by ground
board J1-26, and its ground is to ground board J1-27.
• Inspect the wiring for physical damage.
• Replace ground board.
336 LIFT DN OPEN CIRCUIT The ground board did not • Check for continuity through this circuit. The lift down
detect current flow to the lift solenoid resistance should measure about 20 Ohms.
down solenoid during normal The lift down solenoid is powered (PWM) by ground
operation. board J1-26, and its ground is to ground board J1-27.
• Inspect the wiring for physical damage.
• Replace ground board.
337 STEER LEFT SHORT TO The ground board detected • Check for continuity through this circuit. Steer left
BATTERY voltage while the steer left sole- solenoid resistance should measure about 30 Ohms.
noid was commanded off at The steer left solenoid is powered with 24V from
power up. ground board J1-21, and its ground is to ground
board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.
338 STEER LEFT OPEN CIR- The ground board did not • Check for continuity through this circuit. Steer left
CUIT detect current flow to the steer solenoid resistance should measure about 30 Ohms.
left solenoid during normal The steer left solenoid is powered with 24V from
operation. ground board J1-21, and its ground is to ground
board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.

6-12 31215074
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

3-3 Ground Output Driver

DTC FAULT MESSAGE DESCRIPTION CHECK
339 STEER RIGHT SHORT TO The ground board detected • Check for continuity through this circuit. Steer right
BATTERY voltage while the steer right solenoid resistance should measure about 30 Ohms.
solenoid was commanded off. The steer right solenoid is powered with 24V from
ground board J1-22, and its ground is to ground
board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.
3310 STEER RIGHT OPEN CIR- The ground board did not • Check for continuity through this circuit. Steer right
CUIT detect current flow to the steer solenoid resistance should measure about 30 Ohms.
right solenoid during normal The steer right solenoid is powered with 24V from
operation. ground board J1-22, and its ground is to ground
board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.
3311 GROUND ALARM The ground board detected • Check for continuity through this circuit. The ground
SHORT TO BATTERY voltage while the ground alarm alarm solenoid is powered with 24V from ground
was commanded off. board J1-19, its PWM signal is from ground board J1-
28, and its ground is to ground board J1-30, 37. There
should be about 1500 Ohms between ground alarm
connector pin 1 and pin 3.
• Inspect the wiring for physical damage.
• Replace ground board.
3312 LEFT BRAKE SHORT TO The ground board detected • Check for continuity through this circuit. The left
BATTERY voltage while the left brake was brake is powered with 24V from ground board J1-23,
commanded off. and its ground is to ground board J1-30, 37. Brake
solenoid resistance should measure about 20 Ohms.
• Inspect the wiring for physical damage.
• Replace ground board.
3313 RIGHT BRAKE SHORT TO Voltage was detected on the • Check for continuity through this circuit. Brake sole-
BATTERY right brake solenoid when the noid resistance should measure about 20 Ohms. The
ground board output was com- right brake is powered with 24V from ground board
manded off during power-up. J1-24, and its ground is to ground board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.
3314 LEFT BRAKE OPEN CIR- Current flow to the left brake • Check for continuity through this circuit. The left
CUIT solenoid was not detected brake is powered with 24V from ground board J1-23,
during normal left brake opera- and its ground is to ground board J1-30, 37. Brake
tion. solenoid resistance should measure about 20 Ohms.
• Inspect the wiring for physical damage.
• Replace ground board.
3315 RIGHT BRAKE OPEN CIR- The ground board did not • Check for continuity through this circuit. Brake sole-
CUIT detect current flow to the right noid resistance should measure about 20 Ohms. The
brake during normal operation. right brake is powered with 24V from ground board
J1-24, and its ground is to ground board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.
33297 LEFT BRAKE - SHORT TO Drive and Steer Prevented • Excessive current flow to the Left Brake Solenoid was
GROUND detected (J1-34 NLB).
• ZAPI - HEALTH (Status LED) - ON

31215074 6-13
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

3-3 Ground Output Driver

DTC FAULT MESSAGE DESCRIPTION CHECK
33298 STEER LEFT VALVE - Drive, Steer and Lift Up Pre- • Excessive current flow to the steer left solenoid
SHORT TO GROUND vented detected (J2-9 NLV).
• ZAPI - HEALTH (Status LED) - ON
33299 LINE CONTACTOR COIL - Drive, Lift and Steer Prevented • Voltage from an external source was detected on the
SHORT TO BATTERY Negative Main Line Contactor.
• ZAPI - HEALTH (Status LED) - ON
33302 NEGATIVE SUPPLY - Drive, Lift, and Steer Prevented • At power-up, the system module detected an external
SHORT TO BATTERY short on J1-12, J1-17, J1-23, J2-14 or J2-15. Normally
these pins are grounded by the System Module. All
functions are prevented to protect the control system.
• ZAPI - HEALTH (Status LED) - ON
33303 NEGATIVE SUPPLY - Drive, Lift and Steer Prevented • At power-up, the System Module detected an external
SHORT TO GROUND short on J1-12, J1-17, J2-14 or J2-15. Normally these
pins are grounded by the System Module. Since the
external ground may compromise integrity, all func-
tions will be prevented.
• ZAPI - HEALTH (Status LED) - ON
33304 RIGHT BRAKE - SHORT Drive, and Steer Prevented • Excessive current flow to the Right Brake solenoid was
TO GROUND detected (J1-33 NRB).
• ZAPI - HEALTH (Status LED) - ON
33305 STEER RIGHT VALVE - Drive, Steer, and Lift Up Pre- • Excessive current flow to the Steer Right Solenoid was
SHORT TO GROUND vented detected (J2-18 NRV).
• ZAPI - HEALTH (Status LED) - ON
33383 BEACON LIGHT- OPEN Current flow to the Beacon Out- • Machine Setup's BEACON is 0=NO OR 1=YES
CIRCUIT put was not detected (J1-35 • No motion restrictions
BEAC) • Latched
• ZAPI - HEALTH (Status LED) - ON
33384 BEACON LIGHT - SHORT Excessive current flow to the • Machine Setup's BEACON is 0=NO OR 1=YES
TO GROUND Beacon Output was detected • No motion restrictions
(J1-35 BEAC) • Latched
• ZAPI - HEALTH (Status LED) - ON
33406 LiFT UP VALVE - SHORT Drive, Steer, and Lift Up Pre- • Excessive current flow to the Lift Up Solenlid was
TO GROUND vented detected at (J2-2 PDV or J2-16 NDV).
• ZAPI - HEALTH (Status LED) - ON
33407 LIFT DN VALVE - SHORT Lift Up and Down Prevented • Excessive current flow to the Lift Down Solenoid was
TO GROUND detected (J2-16 NDV).
• ZAPI - HEALTH (Status LED) - ON
33562 BEACON LIGHT - SHORT Voltage from an external source • Machine Setup's BEACON is 0=NO OR 1=YES
TO BATTERY was detected on the Beacon • No motion restrictions
Output (J1-35 BEAC) • Latched
• ZAPI - HEALTH (Status LED) - ON

6-14 31215074
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

4-2 Thermal Limit (SOA)

DTC FAULT MESSAGE DESCRIPTION CHECK
421 POWER MODULE TOO The power module has reached • Power down and allow to cool.
HOT - PLEASE WAIT thermal cutout. • Do not operate in ambients over 140° F (60° C).
• Check for jammed or obstructed drive motors.
• Check for excessively high current consumption in the
pump, ANALYZER -> DIAGNOSTICS -> PUMP -> PUMP
CUR over 130 Amps with an empty platform.
• Check for excessively high traction current consump-
tion, ANALYZER -> DIAGNOSTICS -> TRACTION ->
ARM CUR over 120 Amps while driving on the level.
422 DRIVING AT CUTBACK - The drive portion of the power • Check for jammed or obstructed drive motors.
POWER MODULE CUR- module has reached thermal • Check for excessively high traction current consump-
RENT LIMIT limit. tion, ANALYZER -> DIAGNOSTICS -> TRACTION ->
ARM CUR over 120 Amps while driving on the level.
423 LIFT UP AT CUTBACK - The lift up portion of the power • Check for jammed or obstructed arm stack or pivot
POWER MODULE CUR- module has reached thermal bushing.
RENT LIMIT limit. • Check for excessively high current consumption in the
pump, ANALYZER -> DIAGNOSTICS -> PUMP -> PUMP
CUR over 130 Amps with an empty platform.
• Refer to Pump Motor Electrical Evaluation in Section
4.8.

4-4 Battery Supply

DTC FAULT MESSAGE DESCRIPTION CHECK
441 BATTERY VOLTAGE TOO The power module momentar- • Recharge batteries or check for damaged batteries.
LOW - SYSTEM SHUT- ily measured battery voltage • Check battery charger function.
DOWN under 14.5V between ground
board J1-39 and ground board
J1-40.
442 BATTERY VOLTAGE TOO The power module momentar- • May be due to improper battery charging or incorrect
HIGH - SYSTEM SHUT- ily measured battery voltage > voltage batteries being used.
DOWN 37.0V.
443 LSS BATTERY VOLTAGE The load sensing system mod- • May be due to improper battery charging or incorrect
TOO HIGH ule momentarily measured bat- voltage batteries being used.
tery voltage > 34.0V. • Refer to Section 2.3: Troubleshooting in the LSS man-
ual, 3124288.
444 LSS BATTERY VOLTAGE The load sensing system mod- • Recharge batteries or check for damaged batteries.
TOO LOW ule momentarily measured bat- • Refer to Section 2.3: Troubleshooting in the LSS man-
tery voltage < 9V. ual, 3124288.
446 LOGIC SUPPLY VOLTAGE The system module logic supply • This may be caused by a loose battery terminal,
OUT OF RANGE voltage was measured to be out severely discharged batteries, damaged battery, or an
of normal operating range by improper wire harness connection.
the interface PCB (<11V). • Drive, Steer, and Lift Prevented
• ZAPI - HEALTH (Status LED) - ON
4421 LOGIC SUPPLY VOLTAGE The system module logic supply • This may be caused by a loose battery terminal,
OUT OF RANGE voltage was measured by the severely discharged batteries, damaged battery, or an
power PCB to be more than 34V improper wire harness connection.
for 10uS. • Drive, Steer, and Lift Prevented
• ZAPI - HEALTH (Status LED) - ON

31215074 6-15
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

4-4 Battery Supply

DTC FAULT MESSAGE DESCRIPTION CHECK
4422 LOGIC SUPPLY VOLTAGE The system module logic supply • This may be caused by a loose battery terminal,
OUT OF RANGE voltage was measured by the severely discharged batteries, damaged battery, or an
power PCB to be less than 11V improper wire harness connection.
for 10uS. • Drive, Steer, and Lift Prevented
• ZAPI - HEALTH (Status LED) - ON

6-6 Communication
DTC FAULT MESSAGE DESCRIPTION CHECK
661 CANBUS FAILURE - The control system failed to • Check for 24V between power module 12 position
POWER MODULE receive messages from the connector terminal 1 and the power module B- termi-
power module. nal. If this is the problem, the line contactor may be
cycling on and off, making a clicking noise when the
machine is powered.
• Disconnect ground board J1 and power module con-
nector. Ground board socket J1-31 to power module
connector socket 10 should have continuity. Ground
board socket J1-32 to power module connector
socket 11 should have continuity.
• Turn on machine in platform mode. If DTC 662 is pres-
ent, troubleshoot that DTC before continuing.

6-16 31215074
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

6-6 Communication
DTC FAULT MESSAGE DESCRIPTION CHECK
662 CANBUS FAILURE - PLAT- In platform mode, the control • Turn on machine in ground mode. If DTC 661 is not
FORM MODULE system failed to receive mes- present check for 24V between platform box connec-
sages from the platform board. tor terminals D and A. If not 24V, test continuity from
platform box connector socket A to ground board
connector socket J1-6 and test continuity from plat-
form box connector socket D to ground board con-
nector socket J1-7.
• If DTC 661 was present in the previous check, discon-
nect armstack passthru connector located near the
ladder on the left. Turn on in ground mode. If DTC 661
is not present then there is a problem in armstack har-
ness. Armstack passthru socket 5 to platform box ter-
minal E should have continuity. Armstack passthru
socket 6 to platform box connector terminal F should
have continuity. Armstack passthru socket 7 to plat-
form box connector terminal G should have continu-
ity. Armstack passthru socket 5 to armstack passthru
socket 6 resistance should be 120 Ohms +/- 5%. Arm-
stack passthru socket 5 to armstack passthru socket 7
should measure open circuit. Armstack passthru
socket 6 to armstack passthru socket 7 should mea-
sure open circuit.
• Disconnect armstack passthru and ground board J1.
Armstack passthru pin 5 to ground board socket J1-11
should have continuity. Armstack passthru pin 6 to
ground board socket J1-12 should have continuity.
Armstack passthru pin 7 to ground board socket J1-13
should have continuity. Armstack passthru pin 5 to
armstack passthru pin 6 should measure open circuit.
Armstack passthru pin 5 to armstack passthru pin 7
should measure open circuit. Armstack passthru pin 6
to armstack passthru pin 7 should measure open cir-
cuit.
• Disconnect ground board J1 and power module con-
nector. Ground board socket J1-31 to power module
connector socket 10 should have continuity. Ground
board socket J1-32 to power module connector
socket 11 should have continuity. Ground board
socket J1-31 to J1-32 should measure open circuit.
Ground board socket J1-31 to J1-33 should measure
open circuit. Ground board socket J1-32 to J1-33
should measure open circuit.
• Ensure all connections opened above are recon-
nected. Disconnect power module connector. Turn on
in platform mode. If DTC 662 is no longer present
replace power module.
• If DTC 661 and 662 have been present through above
steps replace ground board.
Continued Next Page

31215074 6-17
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

6-6 Communication
DTC FAULT MESSAGE DESCRIPTION CHECK
662 CANBUS FAILURE - PLAT- In platform mode, the control • Disconnect platform box connector. Open platform
(Cont. FORM MODULE system failed to receive mes- box. Disconnect platform board connector. Platform
) (Continued) sages from the platform board. box socket E to platform board J1-3 should have con-
tinuity. Platform box socket F to platform board J1-4
should have continuity. Platform box pin E to pin F
should measure open circuit. Platform box pin E to pin
G should measure open circuit. Platform box pin F to
pin G should measure open circuit. If these checks are
OK replace platform board.
663 CANBUS FAILURE - LOAD With load sensing system • Check ANALYZER -> MACHINE SETUP -> MODEL NUM-
SENSING SYSTEM MOD- enabled, the control system BER is correct.
ULE failed to receive messages from • Check ANALYZER -> MACHINE SETUP -> MARKET is
the load sensing system mod- correct.
ule. • Check ANALYZER -> MACHINE SETUP -> LOAD is cor-
rect.
• Check for 24V between load sense system module
connector J1-1 and J1-2.
• Turn on machine in platform mode. If DTC 662 is pres-
ent, troubleshoot that DTC before continuing.
• Refer to Section 2.3: Troubleshooting in the LSS man-
ual, 3124288.
664 CANBUS FAILURE - An accessory module has • Turn on machine in platform mode. If DTC 662 is pres-
ACCESSORY MODULE stopped communication. ent, troubleshoot that DTC before continuing.
• See accessory module documentation for trouble-
shooting.
6635 CANBUS FAILURE - Chassis Tilt Sensor messages not • The control system failed to receive messages from
CHASSIS TILT SENSOR received for 1000 mS while B+ is the Chassis Tilt Sensor located inside the Ground Con-
present on J1-28 trol Box.
• Ensure that +B is present on pin 1 of the sensor, and -B
is present on pin 4. Check the CANbus wiring to pins 2
and 3 of the sensor.
• ZAPI - HEALTH (Status LED) - ON

6-7 Accessory
DTC FAULT MESSAGE DESCRIPTION CHECK
671 ACCESSORY FAULT An accessory module is report- • See accessory module documentation for trouble-
ing a fault. shooting.

7-7 Electric Motor

DTC FAULT MESSAGE DESCRIPTION CHECK
771 OPEN CIRCUIT DRIVE The power module detected a • Refer to Drive Motor Electrical Evaluation in Section
MOTOR WIRING problem in the drive motors' 3.5.
power circuit wiring. • Refer to Power Module Electrical Evaluation in Section
3.6.
772 STALLED TRACTION Drive, Steer, and Lift Prevented • The System Module detected armature current feed-
MOTOR OR POWER WIR- back > 4.5V or < 0.5V. This is mostly likely caused by a
ING ERROR stalled traction motor or power wiring issue. Alter-
nately, it could be an internal fault.
• ZAPI - HEALTH (Status LED) - ON

6-18 31215074
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

7-7 Electric Motor

DTC FAULT MESSAGE DESCRIPTION CHECK
773 CAPACITOR BANK Drive, Steer, and Lift Prevented • There is an internal or external fault that prevents the
FAULT - CHECK POWER System Module’s capacitor bank from charging.
CIRCUITS • The System Module detected that the VMN of the
pump and traction has not increased more than 1.3V
in 1000mS. Alternately, the VMN of the pump or trac-
tion is less than 20% of battery voltage.
• If this message persists after disconnecting the drive
and pump wiring, there is an internal fault.
• ZAPI - HEALTH (Status LED) - ON
774 SHORT CIRCUIT FIELD Drive, Steer, and Lift Prevented • The field wiring passed System Module power-up
WIRING diagnostics. However, an external short circuit was
detected when current was applied to F1 / F2. This sit-
uation is caused by improper field wiring or a dam-
aged motor.
• ZAPI - HEALTH (Status LED) - ON
NOTE: Tilt Sensor Calibration is not available when this
condition is present.
775 OPEN CIRCUIT FIELD Drive, Steer, and Lift Prevented • The System Module applied field current, but could
WIRING 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 Drive, Steer, and Lift Prevented • The System Module measured improper pump cur-
OR POWER WIRING rent feedback (>4.5V or <0.5V) for 240mS. This is
ERROR caused by a stalled pump motor, a power wiring
issue, or a System Module malfunction.
• ZAPI - HEALTH (Status LED) - ON
777 OPEN CIRCUIT PUMP Drive, Steer, and Lift Prevented • The System Module measured pump current less
MOTOR WIRING than 8A while the motor voltage was greater than 7V
for 1200mS. This indicates there is an open-circuit
between the System Module’s –P terminal and the
pump motor.
• ZAPI - HEALTH (Status LED) - ON
778 TRACTION T HIGH - Drive, Steer, and Lift Prevented • While driving, the voltage measured at the System
CHECK POWER CIR- Module’s T terminal did not agree with the predicted
CUITS value for at least 300mS. This issue may be caused by
a power wiring error or an internal fault.
• ZAPI - HEALTH (Status LED) - ON
779 TRACTION T LOW - Drive, Steer, and Lift Prevented • While driving, the voltage measured at the System
CHECK POWER CIR- Module’s T terminal did not agree with the predicted
CUITS value for at least 1000mS. This issue may be caused by
an opencircuit of the armature wiring (+B and –T ter-
minals) or an internal fault.
• VMN does not increase more than 1.3V
• VMN is less than 20% Battery Voltage
• Battery Voltage . VMN is greater than 4V
• ZAPI - HEALTH (Status LED) - ON

31215074 6-19
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

7-7 Electric Motor

DTC FAULT MESSAGE DESCRIPTION CHECK
7710 PUMP P HIGH - CHECK Drive, Steer, and Lift Prevented • While steering or lifting up, the voltage measured at
POWER CIRCUITS the System Module’s P terminal did not agree with
the predicted value for at least 240mS. This issue may
be caused by a power wiring error or an internal fault.
• Pump Feedback . Predicted >7V
• ZAPI - HEALTH (Status LED) - ON
7711 PUMP P LOW - CHECK Drive, Steer, and Lift Prevented • While steering or lifting up, the voltage measured at
POWER CIRCUITS the System Module’s P terminal did not agree with
the predicted value for at least 1000mS. This issue
may be caused by an open-circuit of the pump wiring
(+BF2 and –P terminals) or an internal fault.
• Pump feedback does not increase more than 1.3V
• Pump feedback is less than 20% Battery Voltage
• Battery Voltage - pump feedback is greater than 4V
• ZAPI - HEALTH (Status LED) - ON
7741 ARMATURE BRAKING Drive, Steer, and Lift Prevented • The System Module detected excessive braking cur-
CURRENT TOO HIGH rent for more than 5000mS. This can be caused by
transporting an excessive load on a steep grade.
Alternately, this may indicate an internal fault.
• ZAPI - HEALTH (Status LED) - ON
7742 FIELD VOLTAGE Drive, Steer, and Lift Prevented • The System Module voltage at the F1 and F2 termi-
IMPROPER nals 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. If the situation per-
sists after a power cycle, it may be an internal issue.
• ZAPI - HEALTH (Status LED) - ON

8-1 Tilt Sensor

DTC FAULT MESSAGE DESCRIPTION CHECK
811 TILT SENSOR NOT CALI- The tilt sensor calibration has • Calibrate the tilt sensor, see Section 5.2.
BRATED not been performed. • Replace then calibrate tilt sensor, see Section 5.2.
812 NO DATA FROM TILT No signal from tilt sensor. • Check tilt sensor connections and wiring in ground
SENSOR - NOT CON- control box.
NECTED OR FAULTY • Calibrate the tilt sensor, see Section 5.2.
• Replace then calibrate tilt sensor, see Section 5.2.
NOTE: Tilt Sensor cannot be calibrated if main contactor is open due to an alarm.

8-2 Platform Load Sense

DTC FAULT MESSAGE DESCRIPTION CHECK
821 LSS CELL #1 ERROR A problem has been detected • Refer to Section 2.3: Troubleshooting in the LSS man-
with the load sense system. ual, 3124288.
822 LSS CELL #2 ERROR A problem has been detected • Refer to Section 2.3: Troubleshooting in the LSS man-
with the load sense system. ual, 3124288.
823 LSS CELL #3 ERROR A problem has been detected • Refer to Section 2.3: Troubleshooting in the LSS man-
with the load sense system. ual, 3124288.

6-20 31215074
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

8-2 Platform Load Sense

DTC FAULT MESSAGE DESCRIPTION CHECK
824 LSS CELL #4 ERROR A problem has been detected • Refer to Section 2.3: Troubleshooting in the LSS man-
with the load sense system. ual, 3124288.
825 LSS HAS NOT BEEN CAL- The load sensing system mod- • Empty platform. Calibrate LSS, see Section 2.2: Cali-
IBRATED ule has not been calibrated bration in the LSS manual, 3124288.
• Refer to Section 2.3: Troubleshooting in the LSS man-
ual, 3124288.

9-9 Hardware
DTC FAULT MESSAGE DESCRIPTION CHECK
991 LSS WATCHDOG RESET A problem has been detected • Refer to Section 2.3: Troubleshooting in the LSS man-
with the load sense system. ual, 3124288.
992 LSS EEPROM ERROR A problem has been detected • Refer to Section 2.3: Troubleshooting in the LSS man-
with the load sense system. ual, 3124288.
993 LSS INTERNAL ERROR - A problem has been detected • Refer to Section 2.3: Troubleshooting in the LSS man-
PIN EXCITATION with the load sense system. ual, 3124288.
994 LSS INTERNAL ERROR - A problem has been detected • Refer to Section 2.3: Troubleshooting in the LSS man-
DRDY MISSING FROM A/ with the load sense system. ual, 3124288.
D
995 POWER MODULE FAIL- The power module detected an • Record all personality settings in ANALYZER -> PER-
URE - PERSONALITY out-of-range or corrupt person- SONALITIES and ANALYZER -> MACHINE SETUP. Reset
RANGE ERROR ality setting control system personalities to default settings by
selecting a different model than indicated, cycle
power then select proper model. Then, enter person-
ality settings recorded above.
996 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s analog to digital converter does
URE - INTERNAL ERROR not respond for the power PCB. This is an internal fail-
ure.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
997 POWER MODULE FAIL- The power module detected an • Refer to Drive Motor Electrical Evaluation in Section
URE - CHECK POWER error in the power wiring for the 3.5.
CIRCUITS OR MOSFET drive or pump. • Refer to Pump Motor Electrical Evaluation in Section
SHORT CIRCUIT 4.8.
• Refer to Power Module Electrical Evaluation in Sec-
tion 3.6.
998 EEPROM FAILURE - The control system detected an • Replace ground board.
CHECK ALL SETTINGS EEPROM failure.
999 FUNCTION LOCKED The power module software ver- • Replace power module to clear fault.
OUT - POWER MODULE sion is not compatible with the
SOFTWARE VERSION rest of the system.
IMPROPER
9910 FUNCTION LOCKED The platform board software • Reprogram platform board.
OUT - PLATFORM MOD- version is not compatible with
ULE SOFTWARE VER- the rest of the system.
SION IMPROPER

31215074 6-21
 SECTION 6 - DIAGNOSTIC TROUBLE CODES

9-9 Hardware
DTC FAULT MESSAGE DESCRIPTION CHECK
9911 FUNCTION LOCKED The load sensing system mod- • Replace LSS module to clear fault.
OUT - LSS MODULE ule software version is not com-
SOFTWARE VERSION patible with the rest of the
IMPROPER system.
9912 POWER MODULE FAIL- The ground board detected • Refer to Drive Motor Electrical Evaluation in Section
URE - SYSTEM MONITOR armature, field, or pump current 3.5.
while function was not com- • Refer to Pump Motor Electrical Evaluation in Section
manded. 4.8.
• Refer to Power Module Electrical Evaluation in Sec-
tion 3.6.
9917 HIGH RESOLUTION The ground board detected • Pump Motor being turned backwards by a faulty
ANALOG TO DIGITAL armature, field, or pump current check valve in the hydraulic system.
FAILURE - INTERRUPT while function was not com- • Software issue on the controller. Update software.
LOST manded.
9924 FUNCTIONS LOCKED The control system's memory • Use the JLG analyzer to adjust all machine setup and
OUT - MACHINE NOT indicates that the vehicle has personality settings, refer to 5.7 Machine Configura-
CONFIGURED not been configured (new con- tion Programming Information.
trol system components).
9950 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s armature power circuitry is
URE - INTERNAL ERROR driven without PWM command for 100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9951 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s pump power circuitry is driven
URE - INTERNAL ERROR without enable from the interface PCB for 100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9952 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s pump power circuitry is driven
URE - INTERNAL ERROR without PWM command for 100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9953 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s field power circuitry is driven
URE - INTERNAL ERROR without enable from the interface PCB for 100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9954 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s field power circuitry is driven
URE - INTERNAL ERROR without reverse direction from the power PCB for
100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9955 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s field power circuitry is driven
URE - INTERNAL ERROR without forward selection from the power PCB for
100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING

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 SECTION 6 - DIAGNOSTIC TROUBLE CODES

9-9 Hardware
DTC FAULT MESSAGE DESCRIPTION CHECK
9956 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s field current control or MOS-
URE - INTERNAL ERROR FET’s are malfunctioning.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9957 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s hardware that generates an
URE - INTERNAL ERROR interrupt at 36V and 12V did not respond properly at
power-up.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9958 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s pump current measurement or
URE - INTERNAL ERROR MOSFET are malfunctioning.
• Pump current measurement >2.74V or <2.26V for
200mS while idle.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9960 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module detected an issue with the trac-
URE - INTERNAL ERROR tion current measurement or the MOSFET’s.
• Armature current feedback >2.74V or < 2.26V while
idle
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9962 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s temperature feedback is >4.9V
URE - INTERNAL ERROR or <0.1V.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9963 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module detected a mismatch in the
URE - INTERNAL ERROR redundant RAM information stored in the power PCB.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - ON
9964 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s analog to digital converter does
URE - INTERNAL ERROR not respond for the interface PCB.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9969 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s MC/EB/EV/DV Enable is always
URE - INTERNAL ERROR on. This is internal fault.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING

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 SECTION 6 - DIAGNOSTIC TROUBLE CODES

9-9 Hardware
DTC FAULT MESSAGE DESCRIPTION CHECK
9970 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module detected a mismatch in the
URE - INTERNAL ERROR redundant RAM information stored in the interface
PCB.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - ON
9971 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s MC/EB valve activation pin is
URE - INTERNAL ERROR shorted. This is an internal fault.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99143 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s power and interface PCB digital
URE - INTERNAL ERROR inputs do not agree.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99144 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s MC feedback from the interface
URE - INTERNAL ERROR PCB disagrees with the feedback from the power PCB.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99145 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s enable for the power PCB
URE - INTERNAL ERROR requested a drive motor or valve activation when not
expected.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99146 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s lift down feedback voltage to
URE - INTERNAL ERROR the interface and power PCB’s disagrees.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99147 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s VMN feedback voltage to the
URE - INTERNAL ERROR interface and power PCB’s disagrees.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99148 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s setpoint request from the inter-
URE - INTERNAL ERROR face PCB does not match the input state.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99149 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module encountered an unexpected
URE - INTERNAL ERROR software issue.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING

6-24 31215074
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

SECTION 7. GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.1 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.

IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO

WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52
BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE
SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

7.2 MULTIMETER BASICS

A wide variety of multimeters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment. A digital
meter with reasonable accuracy (within 7%) is recommended for the measurements in these procedures. This section
shows diagrams of a common, digital VOM configured for several different circuit measurements. Instructions for your
VOM may vary. Please consult the meter operator’s manual for more information.

Grounding
"Grounding the meter" means to take the black lead (which is connected to the COM (common) or negative port) and
touch it to a good path to the negative side of the voltage source.

Backprobing
To "backprobe" means to take the measurement by accessing a connector’s contact on the same side as the wires, the
back of the connector. Readings can be done while maintaining circuit continuity this way. If the connector is the sealed
type, great care must be taken to avoid damaging the seal around the wire. It is best to use probes or probe tips specifi-
cally designed for this technique, especially on sealed connectors. Whenever possible insert probes into the side of the
connector such that the test also checks both terminals of the connection. It is possible to inspect a connection within a
closed connector by backprobing both sides of a connector terminal and measuring resistance. Do this after giving each
wire a gentle pull to ensure the wires are still attached to the contact and contacts are seated in the connector.

Min/Max
Use of the "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions
while alone. For example, you can read the voltage applied to a solenoid when it is only operational while a switch, far
from the solenoid and meter, is held down.

Polarity
Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are
reversed. Check what reading is expected, the location of the signal and that the leads are connected to the device
under test correctly. Also check that the lead on the "COM" port goes to the ground or negative side of the signal and
the lead on the other port goes to the positive side of the signal.

Scale
M = Mega = 1,000,000 * (Displayed Number)
k = kilo = 1,000 * (Displayed Number)
m = milli = (Displayed Number) / 1,000
µ = micro = (Displayed Number) / 1,000,000
Example: 1.2 k = 1200 
Example: 50 mA = 0.05 A

31215074 7-1
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Voltage Measurement Resistance Measurement

Figure 7-1. Voltage Measurement (DC) Figure 7-2. Resistance Measurement

• If meter is not auto ranging, set it to the correct • First test meter and leads by touching leads
range (See multimeter’s operation manual) together. Resistance should read a short circuit
• Use firm contact with meter leads (very low resistance)
• Circuit power must be turned OFF before testing
resistance
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct
range (See multimeter’s operation manual)
• Use firm contact with meter leads

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 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Continuity Measurement Current Measurement

Figure 7-3. Continuity Measurement Figure 7-4. Current Measurement (DC)

• Some meters require a separate button press to • Set up the meter for the expected current range
enable audible continuity testing • Be sure to connect the meter leads to the correct
• Circuit power must be turned OFF before testing jacks for the current range you have selected
continuity • If meter is not auto ranging, set it to the correct
• Disconnect component from circuit before testing range (See multi meter’s operation manual)
• Use firm contact with meter leads • Use firm contact with meter leads
• First test meter and leads by touching leads
together. Meter should produce an audible alarm,
indicating continuity

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 SECTION 7 - 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 condi-
tion of a particular wire in the harness.

Requirements:
• Harness with at least three separate wires including the wire under test.
• These wires must be able to be isolated from other wires, etc.
• Jumper or method to connect contacts on one side of harness.
• Meter that can measure resistance or continuity.

Procedure
Test multimeter leads resistance. Subtract this value from the measured resistance of the wires to get a more accurate
measurement.
Consult the circuit schematic to determine which wires to use in addition to wire under test, here called wire #1 and wire
#2, and how to isolate these wires. These wires should appear in the same connectors as the wire under test or are within
reach of the jumper.

1. Disconnect all connections associated with the wire under test and the two additional wires. If harness is not com-
pletely isolated disconnect battery terminals also, as a precaution.
2. Measure continuity between all three wires, the wire under test, wire #1 and wire #2. These should be open. If not,
repair the shorted wires or replace the harness.
3. On one side, jumper from contact of wire #1 and wire #2.
4. Measure continuity between wire #1 and wire #2. If there is continuity, both wires are good and can be used for
this test. If there is not continuity, either wire could be bad. Check connections and measurement setup. Redo
measurement. If still no continuity, repair wires or consult schematic for other wires to use for test.
5. Jumper from wire under test to wire #1.
6. Measure continuity. If there is continuity, the wire under test is good. Resistance of a wire increases as the length
increases and as the diameter decreases.
One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem the
third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure.

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 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.3 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. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around
male and female pins on the inside of the connector after the mating of the housing to the header. This is easily
achieved by using a syringe to fill the header with silicone dielectric compound, to a point just above the top of
the male pins inside the header. When assembling the housing to the header, it is possible that the housing will
become air locked, thus preventing the housing latch from engaging.
2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape.
3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it.

7.4 DIELECTRIC GREASE APPLICATION

Dielectric grease helps to prevent corrosion of electrical contacts and improper conductivity between contacts from
moisture intrusion. Non-waterproof connectors benefit from the application of dielectric grease.

Installation
The following is general guidance for the installation of dielectric grease in a connector system.
• Use dielectric grease in a tube for larger connection points or apply with a syringe for small connectors.
• Apply dielectric grease to plug/male connector housing which typically contains sockets contact/female terminals.
• Leave a layer of dielectric grease on the mating face of the connector, completely covering each connector terminal
hole. Refer the pictures shown below.
• Assemble the connector system immediately to prevent moisture ingress or dust contamination.
The following connector systems are specifically addressed because of their widespread use at JLG. However, this guid-
ance may be applied to similar devices.

AMP Mate-N-Lok
This connector system is widely used inside enclosures for general-purpose interconnect. Follow the general guidance
for installation.

Improper Proper

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 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

AMP Faston
This connector system is typically used on operator switches at JLG. Follow the general guidance for installation.

Improper Proper

AMP Micro-Fit
This connector system is typically used on control modules at JLG. Follow the general guidance for installation.

Improper Proper

AMP Mini Fit Jr

This connector system is typically used on control modules at JLG. Follow the general guidance for installation.

Improper Proper

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 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Mini Fit Sr
This connector system is typically used on control modules at JLG. Follow the general guidance for installation.

Improper Proper

DIN Connectors
This connector is typically used on hydraulic valves. Follow the installation instructions

Improper Proper

Exceptions
Some waterproof connector applications do benefit from dielectric grease, and some non waterproof connectors do not
benefit from dielectric grease.
In the exceptions below, we have found dielectric grease is not needed for some applications, and in some cases can
interfere with the intended connection. Dielectric grease shall be used as an exception in other applications.
Enclosures
Application of dielectric grease is not required in properly sealed enclosures. To meet criteria, the enclosure must be
rated to at least IP56 (dust protected; protected from powerful jets of water).

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 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Carling Switch Connectors

Carling switches may experience high impedance, or discontinuity, due to silicone dielectric grease ingress when
switching inductive loads. Therefore, dielectric grease shall not be applied to Carling switch mating connectors unless
specifically noted.
Scissor Platform Cable at the Platform Control
Some waterproof connectors are exposed to the elements when disconnected by the customer benefit from having
protection using dielectric grease.

7.5 AMP CONNECTOR

Figure 7-5. AMP Connector

7-8 31215074
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Assembly
Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 7-6., Connector Assembly (1 of 4)). Pro-
ceed as follows:

Figure 7-6. Connector Assembly (1 of 4)

1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 7-7., Connec-
tor Assembly (2 of 4)).
2. Pull back on the contact wire with a force of 1 or 2 lb to be sure the retention fingers are holding the contact (See
Figure 7-7., Connector Assembly (2 of 4)).
3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the
locking latches by squeezing them inward (See Figure 7-8., Connector Assembly (3 of 4)).
4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-9., Connector Assembly (4 of
4)).

Figure 7-7. Connector Assembly (2 of 4)

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 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-8. Connector Assembly (3 of 4)

Figure 7-9. Connector Assembly (4 of 4)

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 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Disassembly
1. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs.
2. Pry open the wedge lock to the open position.
3. 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.

Figure 7-10. Connector Disassembly

NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.

Wedge Lock
The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field,
by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick.

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 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Service - Voltage Reading

CAUTION
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point.
This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector sys-
tem. The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands.
This nullifies the effectiveness of the connector seals and could result in system failure.

Figure 7-11. Connector Installation

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 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.6 WORKING WITH DEUTSCH CONNECTORS

DT/DTP Series Assembly

Figure 7-12. DT/DTP Contact Installation

1. Grasp crimped contact about 25 mm 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 wedge lock with arrow pointing toward exterior locking mechanism. The
wedge lock will snap into place. Rectangular wedges are not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure for plug.

DT/DTP Series Disassembly

Figure 7-13. DT/DTP Contact Removal

1. Remove wedge lock using needle nose pliers or a hook shaped wire to pull wedge straight out.
2. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by mov-
ing it away from the contact with a screwdriver.
3. Hold the rear seal in place, as removing the contact may displace the seal.

HD30/HDP20 Series Assembly

Figure 7-14. HD/HDP Contact Installation

1. Grasp contact about 25mm behind the contact crimp barrel.
2. Hold connector with rear grommet facing you.

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 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

3. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is prop-
erly locked in place.

CONTACT INSERTION

Figure 7-15. HD/HDP Locking Contacts Into Position

NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing.

HD30/HDP20 Series Disassembly

Figure 7-16. HD/HDP Contact Removal

1. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.
2. Slide tool along into the insert cavity until it engages contact and resistance is felt.
3. Pull contact-wire assembly out of connector.

Figure 7-17. HD/HDP Unlocking Contacts

NOTE: Do Not twist or insert tool at an angle.

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 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.7 SWITCHES
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. Access the terminals to the switch.
4. If the switch has two terminals:
a. Measure resistance across the terminals.
b. Change the switch position.
c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read
an open. If the meter was reading open it should read short.
5. If the switch has more than two terminals, consult the schematic or switch diagram to determine what terminals
will be connected. The test is similar to testing a switch with two terminals.
a. Place one meter lead on the common contact and the other on a different contact in the same circuit.
b. Cycle through all positions of the switch. The meter should read short only when the switch connects the
two terminals and open otherwise.
c. If the switch has more than one common contact repeat the process for that circuit.

Limit Switches
Limit switches are used to control movement or indicate position. Mechanical limit switches are just like manually
operated switches except that the moving object operates the switch. These switches can be tested the same way as
a standard switch by manually operating the sensing arm.
Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Induc-
tive proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch.
They do not require contact, and must be energized to actuate. These types of switches can be used to detect boom
or platform position, for example. These switches have a sensing face where the switch can detect ferrous metal close
to it. To find the sensing face, take note how the switch is mounted and how the mechanisms meet the switch. Test
this type of switch as follows:
1. Remove prox switch from its mount.
2. Reconnect harness if it was disconnected for step a, and turn on machine.
3. Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer. See
vehicle or control system documentation on how to do this.
4. Place sensing face of switch on the object to be sensed by the switch. If that is not available, use a piece of ferrous
metal physically similar to it. The switch state in the control system diagnostics should change.
5. When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between
the switch and object sensed.

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 SECTION 7 - 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. See vehicle or control system documentation on how to
do this.
3. Operate system such that the switch actuates. This could be going over a certain pressure or temperature, for
example. The state indicated in the control system should change.

Switch Wiring - Low Side, High Side

When controlling a load, a switch can be wired between the positive side of the power source and the load. This
switch is called a "high side" switch. The switch supplies the power to the load. When a switch is wired between the
negative side of the power source and the load, it is a "low side" switch. The switch provides the ground to the load.
A low side switch will allow voltage to be present on the load. No power is applied because the switch is stopping
current flow. This voltage can be seen if the measurement is taken with one test lead on the load and the other on the
battery negative side or grounded to the vehicle. What is actually being measured is the voltage drop across the
switch. This could mislead a technician into thinking the load is receiving power but not operating. To produce an
accurate picture of power or voltage applied to the load, measure voltage across the load’s power terminals. Also, the
technician can measure the voltage at both power terminals with respect to battery ground. The difference between
those two measurements is the voltage applied to the load.

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31215074 7-17
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.8 ELECTRICAL SCHEMATICS AND LAYOUTS

8 7 6 5 4

X22-PLATFORM
X3 - GROUND CONTROL TELEMATICS CABLE CONNECTOR; ELEVATION PROX SENSOR (1230ES ONLY)
BOX CONNECTOR; CONNECTS TO X50A CONNECTS TO X22A LOCATED ON FRAME, SENSING MAST;
SEE SHEET 3 SEE SHEET 5-H7 SEE SHEET 5-F5 SWITCH IS 1 43 ELEV PROX
X50 CLOSED WHEN PROXIMITY
1 2 3 4 SEE
H FERROUS MATL SWITCH 2 40-5 BATT RELAY
ZONE
IS PRESENT E-6
12
13
16
17
15
18

14
11
10
1
2

4
9
6
5
8
7

3
5A RED 1-5 BAT POSITIVE

8-3 POS TLT SENSOR

1
4
3
5
6
7
2
8
4-2 KEY PLTF
24-8 BATT NEG
4-1 KEY PLTF

BLACK 24-2 BATTERY NEG

YELLOW CAN-H GND BOX
GREEN CAN-L GND BOX

SW26

23-2 PMC POS LCONT

WIRE IS ONLY LOADED SW25

YELLOW CAN-H PLATF

4 KEY PLTF

GREEN CAN-L PLATF

SEE SHEET ON 1230ES MACHINE
SEE SHEET 2 FOR FOOT
RH-PHP LH-PHP
16 LED YEL

17 LED GND

4 FOR PSL
FUSE

SWITCH
15 LED GRN

SWITCH
14 LED RED

OPTION SWITCH OPTION ON

OTHER MODELS 1 4 1
7 OL GND

4
S48

SP1 (J2-1)
SP11 (J2-11)
SP12 (J2-12)
EPROX (J1-25)

SP9 (J2-7)
SP8 (J2-4)
SP7 (J2-3)
SP6 (J1-35)
SP4 (J1-15)
SP3 (J1-14)
SP2 (J1-24)
G
RED 1-3

SP19 (J1-12)
RED 1-4
SP18 (J1-23)
32 SLPH LT PHP SW
SLPH (J1-11) SP17 (J2-21)
30 PLPH POS LT PHP
PLPH (J1-18) SP16 (J2-20)
33 SRPH RT PHP SW
S46

SRPH (J1-9) SP15 (J2-19)

31 PRPH POS RT PHP
PRPH (J1-19) SP14 (J2-14)
42 FOOT SWITCH
FSW (J1-27)
22 EMS PLATFORM SP13 (J2-13)
S45 EMS (J2-8)
BLACK CAN SHIELD AROTB (J1-2)
24-4 BATTERY NEG

S44 CANS (J2-15)

RED 1-1 BATTERY POS

3-1 E-STOP

YELLOW CAN-H POW MOD PROT (J1-16)

F CANH (J2-6)
GREEN CAN-L POW MOD AROTP (J1-1)
CANL (J2-5)
6 HRMTR NEG
NHRM (J2-23) NROT (J1-17)
7 OL GND
NOVL (J2-22) SMB (J2-10)
9 LIFT UP
SGU (J1-8) PMB (J1-31)
10 LIFT DOWN
SGD (J1-10) NANA (J1-22)
8-2 POS TLT SENSOR * 8-2 POS TLT SENSOR 8-1 POS TILT SEN
S47 PTLT (J1-6) TX (J1-21)
5-2 KEY GRND
GNDS (J1-5) RX (J1-20)
X19 CHARGER 18 SCH CHRGR NTRLK
INTERLOCK SCH (J1-26)
40-2 BATT RELAY PANA (J1-4)
X20 CONNECTOR
FOR 1230ES 40-5 BATT RELAY +BATT (J1-28)
3 CONNECTS TO X20A
SEE SHEET 5-G6 SEE ZONE H-5 23-1 PMC POS LCONT
4 2 40-5 BATT RELAY PMC (J1-13) NRV (J2-18)
FOR SCISSOR'S 41-1 NMC NEG LCONT
E 5 1 40-4 BATT RELAY SEE ZONE E-3 NMC (J1-32) NLV (J2-9)
6 PGAL (J1-7)
40-3 BATT RELAY
S42 CGAL (J1-3)
1
CONNECTS TO X34A NUV (J2-17)
NLB (J1-34)
2 SEE SHEET 5-F6 LB33 23-2 PMC POS LCONT
PLB (J1-29) PDV (J2-2)
CHARGER
BATTERY

NOT USED 1 S40 NRB (J1-33) NDV (J2-16)

BLACK 307 BEACON CTL

2 PRB (J1-30)
S43
X34 POWER CONTROLLER
41-2 NMC NEG LCONT

B+F1 B+F2
+
-

25 CGAL CTL ALARM

23-3 PMC POS LCONT

AH23
#4AWG CABLE P-
BLACK 24-4 BATTERY NEG

40-1 BATT RELAY

GROUND ALARM
BLACK 307-3 BEACON CTL

(SEE SHEET 4 FOR

BLACK 307-4 BEACON CTL

BLACK 24-2 BATTERY NEG

WHITE NOISE MOTION 300A

D S51 C B A ALARM OPTION) B-
26 PGAL POS ALARM

T- B+

C01 C02 X237

F2
87

RED
87a 86 85
J1 J2 X236
F1
BLACK (2-11or1-8)

X403
41-3 NMC NEG LCONT

30
C
B
A
2 2
1 1

X401 RED (2-11or1-8) RED (2-11or1-

23-4 PMC POS LCONT

RL31
BATT RELAY
BLACK (2-11or1-8)
C
B
A
BLACK 307-1A BEACON CTL

ORANGE

C
ORANGE

BROWN
BLACK 24-3 BATTERY NEG
X402 2 1
BLACK 24-1 BATTERY NEG
A1
RIGHT F2

S41
37 NRB NEG RT BRK
1
2

A1

RL32
35 PRB POS RT BRK

MOTOR

LINE
BRAKE

BRAKE

CONTACTOR
A
BLACK 24-7 BATTERY NEG (#14 AWG)
BLACK 42 BEACON CONTROL
S49
BLACK 307-1 BEACON CTL

A2
BLACK 307-2 BEACON CTL

F1

YELLOW

A2

BLACK 24-6 BATTERY NEG (#12AWG)

BLACK 40-6 BATT RELAY

2/0 CABLE
BT39
B-
B
B-3 B-4 X28
RT BR
#2 AWG CABLE

6V 6V YELLOW
1 1
+ +

BATTERY
- -

87 DISCONNECT BROWN
YELLOW

87a 86 85 CONNECTOR
2 2 X27
BROWN

30 B-2 B-1 LT BR
34 PLB POS LT BRK
6V 6V BT38
B+ 36 NLB NEG LT BRK
1 1
RL42
BEACON RELAY
2/0 CABLE 2 2
#2 AWG CABLE
CONNECT X403 AND X401 FOR NO BEACON OPTION
CONNECT X403 AND X402 FOR BEACON OPTION RED 1-2 BATTERY POS (#12AWG)

RED 1-1 BATTERY POS

SHEET 1
8 7 6 5 4

Figure 7-18. Electrical Schematic - Sheet 1 of 10

7-18 31215074
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

5 4 3 2 1

*NOTE: ON BOARD DIAGNOSTICS DISPLAY IS ONLY

AVAILABLE ON 19/20/2630 & 26/3246ES MACHINE'S;

ON 19/20/2630 & 26/3246ES ONLY

ON BOARD DIAGNOSTICS
1 43 ELEV PROX ROTARY ANGLE SENSOR SN21 DISPLAY AND BRAKE
MOUNTED ON BOTTOM ARM ROTARY
PROXIMITY RELEASE BUTTON
PIVOT PIN, GROUND CONTROL SENSOR
SWITCH 2 40-5 BATT RELAY SEE LOCATED ON GROUND
STATION SIDE OF MACHINE; H
ZONE CONTROL STATION SIDE
E-6 OF MACHINE IN
BATTERY COMPARTMENT;

A B C
SEE SHEET 4 X29/X30
ZONE G-8 BRAKE
REL SW 2 5 1 4 6 3
SW26 SW25

19 ARTP ELV SEN NLG

RH-PHP LH-PHP

21 NROT NEG ELV SEN

*NOTE: BRAKE
SWITCH SWITCH RELEASE BUTTON ON
1230ES MACHINE IS
1 4 1 4 AT REAR OF FRAME;

SP1 (J2-1)
SP11 (J2-11)
SP12 (J2-12)
EPROX (J1-25)

SP9 (J2-7)
SP8 (J2-4)
SP7 (J2-3)
SP6 (J1-35)
SP4 (J1-15)
SP3 (J1-14)
SP2 (J1-24)

BLUE 49-90
YEL/RED 2-100
20 PROT POS ELV SEN

WHITE 49-91
BLACK 78
G

SP19 (J1-12)
SP18 (J1-23)
32 SLPH LT PHP SW
SLPH (J1-11) SP17 (J2-21)
30 PLPH POS LT PHP 60 AA MOTION SIG
PLPH (J1-18) SP16 (J2-20)
33 SRPH RT PHP SW SRPH (J1-9) SP15 (J2-19)
31 PRPH POS RT PHP PRPH (J1-19)
4 3 2 1
SP14 (J2-14)
42 FOOT SWITCH
FSW (J1-27) X24
22 EMS PLATFORM SP13 (J2-13) DIAGNOSTIC
EMS (J2-8) CONNECTOR
BLACK CAN SHIELD AROTB (J1-2)
YELLOW CAN-H POW MOD
CANS (J2-15) 20 PROT POS ELV SEN 4 3 2 1
PROT (J1-16)
CANH (J2-6) 19 ARTP ELV SEN NLG F
GREEN CAN-L POW MOD AROTP (J1-1)
CANL (J2-5) 21 NROT NEG ELV SEN
6 HRMTR NEG NROT (J1-17)
NHRM (J2-23)
7 OL GND 38 SMB SW MAN BRK
NOVL (J2-22) SMB (J2-10)
9 LIFT UP 39 PMB POS MAN BRK
SGU (J1-8) PMB (J1-31)
10 LIFT DOWN 29 NANA NEG ANLYZR
SGD (J1-10) NANA (J1-22)
8-1 POS TILT SEN 28 TX ANALYZER
S47 PTLT (J1-6) TX (J1-21)
5-2 KEY GRND 27 RX ANALYZER
GNDS (J1-5) RX (J1-20)
18 SCH CHRGR NTRLK
SCH (J1-26) 27 PANA POS ANLYZR
40-2 BATT RELAY PANA (J1-4)
+BATT (J1-28) X18
23-1 PMC POS LCONT 102 NRV NEG STR RT 102 NRV NEG STR RT
PMC (J1-13) NRV (J2-18) 2 2
41-1 NMC NEG LCONT 101 NLV NEG STR LT 101 NLV NEG STR LT
NMC (J1-32) NLV (J2-9) 1 1
E
PGAL (J1-7) 40-5 BATT RELAY 40-6 BATT RELAY
SEE ZONE E-6 4 4
CGAL (J1-3) 103 NUV NEG LFT UP 103 NUV NEG LFT UP
NUV (J2-17) 3 3
NLB (J1-34)
105 PDV POS LFT DN

S4
PDV (J2-2) 5 5
PLB (J1-29)
106 NDV NEG LFT DN
NRB (J1-33) NDV (J2-16) 6 6

PRB (J1-30)
CYL-HARNESS

40-7 BATT RELAY

40-9 BATT RELAY
40-8 BATT RELAY
POWER CONTROLLER (NO CONNECTOR ON 1230ES)
#4AWG
B+F1 B+F2
25 CGAL CTL ALARM

#4AWG CABLE P-
#4 AWG
+ +
106 NDV NEG LFT DN
105 PDV POS LFT DN

300A
- -
B- PUMP CABLE
D
26 PGAL POS ALARM

T- B+ CONNECTION
*LOCATED AT
ARM PIVOT
C01 C02 X237 BLUE ATTACHMENT ON X40 X41
F2 FRAME
RED

J1 J2 X236
LIFT STEER
F1
BLACK (2-11or1-8)

UP VALVE LEFT VALVE

RED (2-11or1-8) RED (2-11or1-8)

23-4 PMC POS LCONT

STEER
RIGHT VALVE
BLACK (2-11or1-8)
X43 X42
ORANGE
LIFT
C
ORANGE
ORANGE

DOWN VALVE LOCATED ON

BROWN CYL PORT BLOCK
1
A1
RIGHT F2
37 NRB NEG RT BRK

A1

F2
35 PRB POS RT BRK

MOTOR

PUMP
BRAKE

MOTOR
BRAKE

#4AWG MOTOR
MOTOR
LEFT F1
A

+ MOTOR -
A2
F1

YELLOW

A2

BLUE #4AWG

X28 B
RT BR
#2 AWG CABLE

YELLOW
1 1 BROWN
YELLOW

2 2 X27
BROWN

LT BR
34 PLB POS LT BRK
36 NLB NEG LT BRK
1 1
2 2
#2 AWG CABLE

SHEET 1 1001166759-I
5 4 3 2 1

MAF22950I

Figure 7-19. Electrical Schematic - Sheet 2 of 10

31215074 7-19
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

8 7 6 5 4

RED 9
PLATFORM J3-1
H ALARM RED 14-3 DIGITAL
RIBBON CAPACITY
OUTPUT SWITCH
DRIVERS CABLE
CONNECTOR LOADING ANALOG INPUT (24 V WHEN J3-7
AT JOYSTICK FILTER OUTPUT IS ON)
0 TO 5 VOLT
J1-12
JOYSTICK COMMON RED (22GA)- 1 RED 14-2
J1-1
MICRO-
TRIGGER VIOLET (22 GA)- 2 BLACK PROCESSOR BROWN/PURPLE 19
J1-8 J1-11
ROCKER LEFT GREEN (24 GA)- 5 DIGITAL INPUT LIFT DRIVE
BLUE 11 ORANGE/WHITE 17
J1-15 FILTER (24 V J1-9
RT LT ROCKER RIGHT YELLOW (24 GA)- 4 BROWN 12 DIGITAL WHITE/GREEN 18
J1-16 INPUTS) J1-10
+5VDC WHT/RED- 7 PINK 5 (ACTIVE HIGH)
J1-5
G GROUND WHT/BLACK- 8 PURPLE 6
OPTIONAL
J1-7 1230ES ONLY;
0-5 VOLT SIG OUTPUT BROWN- 9 POWER CAN
WHITE 7 DISTRIBUTION FOOT
OUTPUT J1-6 INTERFACE
AND REGULATION J4-1 SWITCH
BLACK (TO ALL AREAS RIBBON HORN
J1-2
OF THE SYSTEM) CABLE BUTTON
BLACK 16
RED 14-1

GREEN J4-7
J1-3
BLACK
*CAPACITY & HORN SWITCHES
YELLOW
J1-4 ARE MOUNTED IN DIECASTING
SHIELD AND ATTACHED TO PCB VIA
ESTOP

RIBBON CABLE.

RED
RED 16-1
F

PLATFORM CONTROL BOX

D

H
G
A
C
B

BLACK
YELLOW (1230ES ONLY)

WHITE

18-2_CABLE
ORANGE

YELLOW

SHIELD
GREEN
BLACK

120 /.250 WATT RESISTOR

BLUE
RED

E ASSEMBLED IN CIRCULAR PLUG

OF CABLE AT PLATFORM BOX
CONNECTION; (19/20/2630 & 26/3246ES ONLY)
1 2 3 4 5 6 7 8
COIL CABLE IN PLATFORM ATTACHED TO RAILS;
CONNECTS TO TWIN CABLE UNDERNEATH
PLATFORM NEAR ARM PIVOT AND TO PLATFORM
CONTROL BOX; BLACK 2
YEL/RED 2-5-9
YEL/RED 2-4-2
YEL/RED 2-2-3

TWIN CABLE
CONNECTION
D UNDER
PLATFORM;
YEL/RED 2-5-8
BLACK 1

SHIELD
BLACK
RED
RED
BLACK
SHIELD
C

TO CONTROLLER FOOT
J1-(27) FSW
1 2 3 4 5 6 7 8 (SHEET 1 ZONE F-4) SWITCH

1 1 1 1
42 FOOT SWITCH WHT WHT WHT

S1905
22 EMS PLATFORM-1
2 2 BLK BLK
2 2 BLK
YELLOW (1230ES ONLY)

B
ORANGE

YELLOW

SHIELD
GREEN
BLACK

22 EMS PLATFORM

CONNECT TO X417 ON
BLUE

OPTIONAL
RED

CAN SPLICE HARNESS FOOT SWITCH W/O LSS

IN FRAME NEAR ARM 19/20/2630/26/3246ES ONLY
PIVOT ATTACHMENT; 1 2 3 4 5 6 7 8
SEE SHEET 5-F3
1 2 3 4 5 6 7 8

A TO X22 PIN 2
(SEE SHEET 1
22 EMS PLATFORM-2 ZONE H-6)

SHEET 2
8 7 6 5 4

Figure 7-20. Electrical Schematic - Sheet 3 of 10

7-20 31215074
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

5 4 3 2 1

J3-1 H
RIBBON CAPACITY
CABLE SWITCH
J3-7

BROWN/PURPLE 19
J1-11
LIFT DRIVE
ORANGE/WHITE 17
J1-9
WHITE/GREEN 18
J1-10

OPTIONAL G
1230ES ONLY;

FOOT
J4-1 SWITCH
RIBBON HORN
CABLE BUTTON
J4-7 OPTIONAL
*CAPACITY & HORN SWITCHES
ARE MOUNTED IN DIECASTING
19/20/2630 &
AND ATTACHED TO PCB VIA 26/3246ES
RIBBON CABLE.
ONLY;

FOOT
SWITCH F

PLATFORM CONTROL BOX

BLACK

WHITE

18-2_CABLE

LSS MODULE LOCATED AT TOP

OF ARMSTACK UNDER PLATFORM
E
(19/20/2630 & 26/3246ES ONLY)
LOAD SENSE PLATFORM MOUNTING ARM
MODULE PINS FOR LOAD SENSE
WHITE
J1-11 (+B-2; CONNECTS TO +B) +SIGNAL-1 1:+SIGNAL
BLACK
J1-9 (D11; HIGH-SENSING DIG INPUT) CAL CLOCK-2 2:CAL CLOCK
BLACK 2
J1-3 (GND-2; CONNECTS TO GND)
FL
J5
-EXCITE-3 3:-EXCITE
YEL/RED 2-5-9
J1-12 (+B-2; CONNECTS TO +B) +EXCITE-4 4:+EXCITE PIN
J1-5 (DO1; HIGH-SIDE DIG OUTPUT) -SIGNAL-5 5:-SIGNAL
J1-6 (DO2; HIGH-SIDE DIG OUTPUT) CAL DATA-6 6:CAL DATA
X262-J1

J1-7 (DI3; HIGH-SENSING DIG INPUT) +SIGNAL-1 1:+SIGNAL

J1-8 (DI2; HIGH-SENSING DIG INPUT) 2:CAL CLOCK
D
CAL CLOCK-2
J1-4 (N/C; UNUSED) 3:-EXCITE FR
J6
-EXCITE-3
J1-10 (GND-2; CONNECTS TO GND) +EXCITE-4 4:+EXCITE PIN
YEL/RED 2-5-8 J1-1 (+B; PWR SUP FROM HOST CNTL SYS) -SIGNAL-5 5:-SIGNAL
BLACK 1 J1-2 (GND; GROUND FROM HOST CNTL SYS) CAL DATA-6 6:CAL DATA
SHIELD 1:+SIGNAL
J2-8 (CANS-2; CONNECTS TO CANS-1) +SIGNAL-1
BLACK J2-7 (CANL-2; CONNECTS TO CANL-1) CAL CLOCK-2 2:CAL CLOCK
RED J2-6 (CANH-2; CONNECTS TO CANH-1) 3:-EXCITE RL
J7
-EXCITE-3
RED
J2-4 (CANH-1; CANbus INTERFACE HIGH) +EXCITE-4 4:+EXCITE PIN
BLACK J2-9 (CANL-1; CANbus INTERFACE LOW) -SIGNAL-5 5:-SIGNAL
SHIELD J2-5 (CANS-1; SHIELD TERMINATION (NOT GND) CAL DATA-6 6:CAL DATA
C
X263-J2

J2-3 (TRP-1; 120 OHM CANbus TERMINATOR) +SIGNAL-1 1:+SIGNAL

FOOT J2-10 (TRP-2; 120 OHM CANbus TERMINATOR) CAL CLOCK-2 2:CAL CLOCK
SWITCH J2-1 (APWR; PRE-REGULATED SUPPLY FOR JLG ANALYZER) -EXCITE-3 3:-EXCITE RR
J2-2 (TX; RS-232 FOR JLG ANALYZER)
J8 +EXCITE-4 4:+EXCITE PIN
J2-11 (RX; RS-232 FOR JLG ANALYZER) -SIGNAL-5 5:-SIGNAL

1 WHT WHT
1 1 WHT
J2-12 (GND; GROUND FOR JLG ANALYZER) CAL DATA-6 6:CAL DATA

2 BLK BLK
2 2 BLK

SHEET 2 1001166759-I
5 4 3 2 1

MAF22960I

Figure 7-21. Electrical Schematic - Sheet 4 of 10

31215074 7-21
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

8 7 6 5 4

KEYSWITCH
3-2 E-STOP
G
FC12 FC13 SW7 SW8
1 B+ B, SW9

1, SW10 3, SW11
CIR_BREAKER ESTOP PLATFORM GROUND
POSITION POSITION

1 3-1 E-STOP
2 4 KEY PLATF
3 5-2 KEY GRND
4 5-1 KEY GRND
5 9 LIFT UP

E 6 10 LIFT DOWN

7 6 HRMTR NEG

9 8-1 VCC

8 7 OL GND
RED 11 CANH
10 BLACK 12 CANL
11 BROWN 13 TLT GND
12
D
13
14 14 LED RED
15
16 15 LED GRN

17 16 LED YEL

SN5
18 BROWN 17 LED GND
4 3 2 1
C
GROUND BOX BULKHEAD
1 2 3 4 X4
CONNECTOR;
NOT USED
CONNECTED TO X3
ON CHASSIS HARNESS

DUAL AXIS
TILT SENSOR
B

SHEET 3
8 7 6 5 4

Figure 7-22. Electrical Schematic - Sheet 5 of 10

7-22 31215074
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

5 4 3 2 1

KEYSWITCH
3-2 E-STOP SW6
B, SW9 LIFT SWITCH
G

1, SW10 3, SW11
HOUR METER

DOWN
GD15
GROUND 00000

UP
PLATFORM
POSITION POSITION
GD14

4 KEY PLATF
5-2 KEY GRND
5-1 KEY GRND
9 LIFT UP
10 LIFT DOWN
6 HRMTR NEG
8-1 VCC E

7 OL GND
RED 11 CANH
BLACK 12 CANL
BROWN 13 TLT GND

OPTIONAL
D
LB17 LB16 8-2 VCC

SN5 OVERLOAD
4 3 2 1 LAMP

8-3 VCC
C

DUAL AXIS
TILT SENSOR

GROUND CONTROL BOX

SHEET 3 1001166759-I
5 4 3 2 1

MAF22970I

Figure 7-23. Electrical Schematic - Sheet 6 of 10

31215074 7-23
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

8 7 6 5 4

WHITE NOISE MOTION ALARM

H 60 AA MOTION SIG
61 AA MOTION OUT

87
WHITE NOISE 87a 85 86
MOTION
30
RL1904
ALARM RELAY

AH23 26 PGAL POS ALARM

26-3 PGAL POS ALARM
26-2 PGAL POS ALARM AH23A
S1901
26-1 PGAL POS ALARM
A A A A
CONNECT TO AH23 B B
25 CGAL CTL ALARM 25 CGAL CTL ALARM
B B
BLK 24-3 BATTERY NEG BLK 24-3-3 BATTERY NEG
(SEE SHEET 1 D-6) C C C C

S1902
F
AH1903
61 AA MOTION OUT
A A
BLK 24-3-1 BATTERY NEG
B B

E
X3 LB66
1
YEL 3-2-1 IGN

FRONT BEACON
2
PSL
BLK 1-2-1 GND
BLACK

RED

ORANGE

ORANGE

LB33 ON SHEET 1

D 1 YEL 3-2 IGN

CONNECTS TO

BLK 1-2 GND

2

X65

SONIC WELDS
BLACK
12
ORANGE
1
FUSE
10A

C
BLACK
X1911
2
1
2
1

B
SEE SHEET 1 H-8/
SHEET 3 C-8
FROM CHASSIS BLACK 24-4
HARNESS X3 - GROUND CONTROL
TO GROUND RED 1-3 BOX CONNECTOR;
CONTROL AT CHASSIS
HARNESS

PROGRAMMABLE SECURITY LOCK OPTION

A

SHEET 4
8 7 6 5 4

Figure 7-24. Electrical Schematic - Sheet 7 of 10

7-24 31215074
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

5 4 3 2 1

Rl1904

AH23A
A A HORN, ARMGUARD &
25 CGAL CTL ALARM
B B OVERLOAD ALARM
BLK 24-3-3 BATTERY NEG C C (SEE SHEET 1 D-6)

F
AH1903
61 AA MOTION OUT
A A WHITE NOISE
B B
BLK 24-3-1 BATTERY NEG
ALARM

YEL 3-2-1 IGN E

LB66
1

FRONT BEACON
2

BLK 1-2-1 GND

YEL 3-2-2 IGN

LB67
1
S68
LB33 ON SHEET 1

1 YEL 3-2 IGN REAR BEACON

CONNECTS TO

D
BLK 1-2 GND BLK 1-2-2 GND
2 S69 2

X65

TWO BEACON OPTION

(IF ONE BEACON,JUST CONNECT LB33 TO THE BEACON) C

SHEET 4 10011667594-I
5 4 3 2 1

MAF22980I

Figure 7-25. Electrical Schematic - Sheet 8 of 10

31215074 7-25
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

8 7 6 5 4

HARNESS,CHARGER, 24VDC, J1939

X2A
WHT 8-3 PLAT ENABLE WHT 8-3 PLAT ENABLE
4 4 4
ORG 4-3 IGN S414 IP408 S410 ORG 4-5 IGN ORG 2-0 IGN
3 3 3
TO X50 BLK 24-8 BAT- 1A S413 IP409 BLK 24-8 BAT- BLK 0-0 GND
S1-H7 2 2 2
RED 1-5 BAT+ RED 1-5 BAT+ RED 1-0 BAT
1 1 1
X50A X2
DELTA Q CHARGER IC650
3 x 4 BUSS BAR
X20A
CO399 RED 18-1 INTL NC
2 TO X20
CHGR CAN SHIELD RED 40-4 INTL COM
CAN GND 1 1 S1-E7
RED 18-1 INTL NC
INT NC 2
G RED 40-4 INTL COM IP407

11
12

10
MS418
1
2

3
4
9

5
6
7
8
INT COM 3
RED 2-3 INTL NO S412 1A S411
INT NO 4
RED 1-8 BATT TEMP+
BATT TEMP+ 5
CAN HIGH RED CHGR CAN HI X404
6
RED CHGR CAN HI RED CHGR CAN HI
7 A A
BLK CHGR CAN LO B BLK CHGR CAN LO
8 B
CHGR CAN SHIELD CHGR CAN SHIELD
9 C C
BLK CHGR CAN LO RED PT7 CAN HI
CAN LOW 10 CAN CABLE X404A CAN CABLE BLK PT7 CAN LO
11
Pt7 CAN SHIELD
12 SN424
RED 1-8 BATT TEMP+
13 1 1
BLK 24-11 BATT TEMP NEG BLK 24-11 BATT TEMP NEG CAN CABLE
BATT TEMP NEG 14 2 2
T421 X34A
WHT 1-7 BATT POS 12 AWG SN424A
BATT POS 1 1 TO X34
BATT NEG 1 BLK 24-10 BATT NEG 12 AWG 2 S1-D7
T422 RED 4-1 KEY PLTF RED 4-1 KEY PLTF
1
F BLU 22-1 EMS PLATFORM BLU 22-1 EMS PLATFORM
2
HARNESS,CHARGER, 24VDC POWER ORG 23-2 PMC POS LCONT ORG 23-2 PMC POS LCONT
3
BLK 24-2 BATTERY NEG BLK 24-2 BATTERY NEG
TO X22 4
POWER CABLE/PLUG RED CAN HI RED CAN HI
S1-H7 5
BLK CAN LO BLK CAN LO
6
BATTERY CHARGER CAN SHIELD CAN SHIELD
7
INPUT: 85-270VAC, 50/60HZ, 7.5A MAX YEL 42-1 FOOT SWITCH YEL 42-1 FOOT SWITCH
OUTPUT: 24-36VDC, 27.1A MAX 8
CAN CABLE CAN CABLE
X22A

HARNESS,ES, CAN SPLICE

SHEET 5
8 7 6 5 4

Figure 7-26. Electrical Schematic - Sheet 9 of 10

7-26 31215074
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

5 4 3 2 1

X1
3 x 4 BUSS BAR
1
2
3
ORG 2-0 IGN
4
11
12

10
MS418
1
2

3
4
9

5
6
7
8

YEL CAN IH-2

5 G
A 6
GRN CAN IL-2 S002 GRN CAN IL-3
B 7
C 8
RED CHGR CAN HI
9
BLK CHGR CAN LO MS423-1A S001
10
CHGR CAN SHIELD X423 11
RED PT7 CAN HI YEL CAN 1H-1
CAN CABLE A A 12
BLK PT7 CAN LO GRN CAN IL-1 TCU
B B 13
Pt7 CAN SHIELD C
C 14
MS423-1B 15
CAN CABLE
16
YEL CAN IH-3 17
18
X417 19
RED 4-1 KEY PLTF RED 4-1 KEY PLTF
1 1 20
BLU 22-1 EMS PLATFORM BLU 22-1 EMS PLATFORM
2
ORG 23-2 PMC POS LCONT
2 21 F
ORG 23-2 PMC POS LCONT TO 8-POS PLUG
3 3 22
BLK 24-2 BATTERY NEG BLK 24-2 BATTERY NEG ON PLATFORM/AC CABLE BLK 0-0 GND
TO X22 4 4 23
RED CAN HI RED CAN HI S2-A8 RED 1-0 BAT
S1-H7 5 5 24
BLK CAN LO BLK CAN LO
6 6
CAN SHIELD CAN SHIELD
7 7
YEL 42-1 FOOT SWITCH YEL 42-1 FOOT SWITCH
8 8
CAN CABLE CAN CABLE
X22A
HARNESS,EBOOM CLEARSKY CAN

HARNESS,ES, CAN SPLICE

SHEET 5 1001166759-I
5 4 3 2 1

MAF22990I

Figure 7-27. Electrical Schematic - Sheet 10 of 10

31215074 7-27
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-28. Electrical Components Layout

7-28 31215074
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-28., Electrical Components Layout

31215074 7-29
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.9 HYDRAULIC SCHEMATIC

Figure 7-29. Hydraulic Schematic - USA Manufactured

7-30 31215074
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-29., Hydraulic Schematic - USA Manufactured

31215074 7-31
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-30. Hydraulic Schematic - China Manufactured

7-32 31215074
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-30., Hydraulic Schematic - China Manufactured

31215074 7-33
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7-34 31215074
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1 JLG Drive
McConnellsburg, PA 17233-9533 USA
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(877) 554-5438 (Customer Support)
(717) 485-6417

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