Service & Maintenance Manual

1 Service & Maintenance Manual Models 1930ES. 2030ES. 2630ES. 2646ES. 3246ES. 3121166. November 27, 2013. INTRODUCTION - Maintenance SAFETY PRECAUTIONS. SECTION A. INTRODUCTION - Maintenance SAFETY PRECAUTIONS. A. GENERAL C. Maintenance . This section contains the general safety precautions which must be observed during Maintenance of the aerial platform. It is of utmost importance that mainte- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN. nance personnel pay strict attention to these warnings THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL. and precautions to avoid possible injury to themselves INJURY OR DEATH AND IS A SAFETY VIOLATION. or others, or damage to the equipment. A Maintenance program must be followed to ensure that the machine is safe to operate. ENSURE REPLACEMENT PARTS OR COMPONENTS ARE. IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR.

2 COMPONENTS. NO SMOKING IS MANDATORY. NEVER REFUEL DUR- ING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS. MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A CLOSED AND SECURE AT ALL OTHER TIMES. RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS. SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION. REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN. PERFORMING ANY Maintenance . The specific precautions to be observed during mainte- DO NOT WEAR LONG HAIR UNRESTRAINED, OR. nance are inserted at the appropriate point in the man- LOOSE-FITTING CLOTHING AND NECKTIES WHICH. ual. These precautions are, for the most part, those that ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN. apply when servicing hydraulic and larger machine EQUIPMENT. component parts. OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS. Your safety, and that of others, is the first consideration ON MACHINE AND IN Service Manual .

3 When engaging in the Maintenance of equipment. KEEP OIL, GREASE, WATER, ETC. WIPED FROM STAND- Always be conscious of weight. Never attempt to move ING SURFACES AND HAND HOLDS. heavy parts without the aid of a mechanical device. Do USE CAUTION WHEN CHECKING A HOT, PRESSURIZED. not allow heavy objects to rest in an unstable position. COOLANT SYSTEM. When raising a portion of the equipment, ensure that adequate support is provided. NEVER WORK UNDER AN ELEVATED SCISSOR UNTIL. PLATFORM HAS BEEN SAFELY RESTRAINED FROM. ANY MOVEMENT BY BLOCKING OR OVERHEAD. SLING, OR SAFETY PROP HAS BEEN ENGAGED. SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL BEFORE MAKING ADJUSTMENTS, LUBRICATING OR. OVER THE FIELD INSPECTION AND Maintenance , SAFETY IN PERFORMING ANY OTHER Maintenance , SHUT OFF. THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR. ALL POWER CONTROLS.

4 BATTERY SHOULD ALWAYS BE DISCONNECTED DUR- B. HYDRAULIC SYSTEM SAFETY ING REPLACEMENT OF ELECTRICAL COMPONENTS. It should be noted that the machines hydraulic systems KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS. operate at extremely high potentially dangerous pres- STOWED IN THEIR PROPER PLACE. sures. Every effort should be made to relieve any system USE ONLY APPROVED, NONFLAMMABLE CLEANING. pressure prior to disconnecting or removing any por- SOLVENTS. tion of the system. Relieve system pressure by cycling the applicable con- trol several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss. 3121166 JLG Lift a INTRODUCTION - Maintenance SAFETY PRECAUTIONS. REVISION LOG. NOTE: All machines built before mid-year 2010 are equipped with the Sevcon-1600346 Power Module, in mid-year 2010 a new design ZAPI-1001092456 Power Module was introduced for production.

5 ES Scissors built in the USA and Belgium may be equipped with either one of two different power modules after mid-2010. All China built machines were equipped the ZAPI-1001092456 Power Module. If power module Service is required, see Section-3 in order to locate and identify which power module your machine is equipped with. Original Issue - May 27, 2003. Revised - October 31, 2003. Revised - March 19, 2004. Revised - July 8, 2004. Revised - July 27, 2004. Revised - October 22, 2004. Revised - May 4, 2005. Revised - July 27, 2005. Revised - May 9, 2006. Revised - September 6, 2006. Revised - September 28, 2006. Revised - November 22, 2006. Revised - April 27, 2007. Revised - August 27, 2007. Revised - January 11, 2008. Revised - July 30, 2008. Revised - November 4, 2008. Revised - October 8, 2009. Revised - June 1, 2010. Revised - August 30, 2011.

6 Revised - October 3, 2012. Revised - November 27, 2013. b JLG Lift 3121166. TABLE OF CONTENTS. TABLE OF CONTENTS. SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - Maintenance SAFETY PRECAUTIONS. A General .. a B Hydraulic System Safety .. a C Maintenance .. a SECTION 1 - SPECIFICATIONS. Specifications .. 1-1. Capacities .. 1-2. Fluid Capacities .. 1-2. Tires .. 1-3. Batteries .. 1-3. Motors .. 1-3. Battery Charger .. 1-3. Travel Speed.. 1-4. Lift Speed (No Load in Platform) .. 1-4. Model Dimensions .. 1-5. Torque Requirements .. 1-6. Lubrication.. 1-6. Hydraulic Oil .. 1-6. Limit Switches.. 1-7. Tilt Alarm .. 1-7. High Drive Speed Cutout .. 1-7. Pressure Settings .. 1-7. Cylinder Specifications .. 1-8. Major Component Weights .. 1-8. Critical Stability Weights .. 1-8. Torque ChartS.. 1-9. SECTION 2 - GENERAL. Machine Preparation, Inspection, and Maintenance .

7 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. 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 .. 2-2. 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. Lubrication and Information .. 2-4. 3121166 JLG Lift i TABLE OF CONTENTS. Hydraulic System .. 2-4. Hydraulic Oil.. 2-4. Changing Hydraulic Oil .. 2-4. Lubrication Specifications .. 2-4. Cylinder Drift Test.

8 2-5. Platform Drift .. 2-5. Cylinder Drift .. 2-5. Pins and Composite Bearing Repair Guidelines .. 2-5. Preventive Maintenance and Inspection Schedule .. 2-6. SECTION 3 - CHASSIS & SCISSOR ARMS. Diagnostic Port.. 3-1. MDI (Multifunction Digital Indicator) and brake release .. 3-1. Traction System .. 3-3. Theory of Operation .. 3-3. Torque Hub .. 3-5. Roll Test .. 3-5. Leak Test .. 3-5. Oil Check/Fill Procedure.. 3-5. Manual Disengage Procedure .. 3-6. Manual Disengage Procedure .. 3-7. Manual Disengage Procedure .. 3-8. Motor and Brake Disassembly .. 3-9. Motor Disassembly .. 3-10. Drive Motor Removal .. 3-11. Main Gearbox Disassembly .. 3-12. Input Carrier Disassembly .. 3-13. Hub Disassembly .. 3-14. Spindle Disassembly .. 3-15. Spindle Sub-Assembly .. 3-16. Hub Sub-Assembly .. 3-17. Input Carrier Sub-Assembly .. 3-18. Main Gearbox Assembly.

9 3-19. Motor and Brake Assembly .. 3-21. Motor Assembly .. 3-23. Motor Assembly .. 3-24. Tightening and Torquing Bolts .. 3-25. Assembly Tools .. 3-25. Electric Drive Motor .. 3-26. Disassembly .. 3-26. Replacing Motor Bearing .. 3-26. Inspecting Motor Brushes .. 3-26. Replacing Motor Brushes.. 3-26. Replacing the Motor Cable .. 3-26. Reassembling the Motor .. 3-27. Motor Maintenance .. 3-28. Disassembly .. 3-29. Inspection and Service .. 3-30. Reassembly.. 3-30. Electric Drive Motor .. 3-32. Drive Motor Troubleshooting .. 3-33. Drive Motor Disassembly.. 3-33. Drive Motor Inspection and Service .. 3-33. Drive Motor Reassembly .. 3-34. Drive Motor Servicing Guidelines .. 3-35. Drive Motor Electrical Evaluation.. 3-36. Servicing Guidelines .. 3-36. ii JLG Lift 3121166. TABLE OF CONTENTS. Common Traction System Difficulties .. 3-37. Power Module - Sevcon.

10 3-38. Power Module Electrical Evaluation.. 3-39. Power Module - ZAPI .. 3-40. ZAPI Power Module Electrical Evaluation.. 3-41. Battery Removal.. 3-42. Battery Maintenance and Safety Practices.. 3-43. Battery Charger .. 3-43. Battery Charger Maintenance .. 3-44. Battery Charger Troubleshooting .. 3-45. Battery Charger/Inverter (Option) .. 3-48. Battery Charger/Inverter Troubleshooting .. 3-49. Drive Motor Cable Routing.. 3-50. Pothole Switch Replacement .. 3-55. Rotary Angle Sensor Replacement .. 3-59. Ground Control Station .. 3-59. Printed Circuit Board (PCB) Replacement .. 3-59. Tilt Sensor Replacement.. 3-60. Arms and Platform Positioning and Support.. 3-62. Platform Removal .. 3-63. Scissor Arms Removal .. 3-63. Platform Control Station .. 3-65. Joystick Controller .. 3-66. SECTION 4 - HYDRAULICS. Cylinders - Theory of Operation .. 4-1. Valves - Theory of Operation.