JLG 1930ES 2030ES 2630ES 2646ES 3246ES Service And Maintenance Manual 3121166 2010

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JLG 1930ES 2030ES 2630ES 2646ES 3246ES Service And Maintenance Manual 3121166 2010
Size: 12.05 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Electric Scissor Lift
Type of Manual: Service And Maintenance Manual, Hydraulic And Electric Wiring Diagram
Model: JLG 1930ES 2030ES 2630ES 2646ES 3246ES
Date: 2010
Parts Number: 3121166
Number of Pages: 212 Pages

Contents:
Service & Maintenance Manual

Section A. Introduction - Maintenance Safety Precautions​

A.A General​

A.B Hydraulic System Safety​

A.C Maintenance​

Section 1. Specifications​

1.1 Specifications​

Capacities​

Fluid Capacities​

Tires​

Batteries​

Motors​

Battery Charger​

Travel Speed​

Lift Speed (No Load in Platform)​

Model Dimensions​

1.2 Torque Requirements​

1.3 Lubrication​

Hydraulic Oil​

1.4 Limit Switches​

Tilt Alarm​

High Drive Speed Cutout​

Pressure Settings​

1.5 Cylinder Specifications​

1.6 Major Component Weights​

1.7 Critical Stability Weights​

1.8 Torque ChartS​

Section 2. General​

2.1 Machine Preparation, Inspection, and Maintenance​

General​

Preparation, Inspection, and Maintenance​

Pre-Start Inspection​

Pre-Delivery Inspection and Frequent Inspection​

Annual Machine Inspection​

Preventative Maintenance​

2.2 Service and Guidelines​

General​

Safety and Workmanship​

Cleanliness​

Components Removal and Installation​

Component Disassembly and Reassembly​

Pressure-Fit Parts​

Bearings​

Gaskets​

Bolt Usage and Torque Application​

Hydraulic Lines and Electrical Wiring​

Hydraulic System​

Lubrication​

Battery​

Lubrication and Servicing​

2.3 Lubrication and Information​

Hydraulic System​

Hydraulic Oil​

Changing Hydraulic Oil​

Lubrication Specifications​

2.4 Cylinder Drift Test​

Platform Drift​

Cylinder Drift​

2.5 Pins and Composite Bearing Repair Guidelines​

2.6 Preventive Maintenance and Inspection Schedule​

Section 3. Chassis & Scissor Arms​

3.1 Diagnostic Port​

3.2 MDI (Multifunction Digital Indicator) and brake release​

3.3 Traction System​

Theory of Operation​

3.4 Torque Hub​

Roll Test​

Leak Test​

Oil Check/Fill Procedure​

Manual Disengage Procedure​

Manual Disengage Procedure​

Manual Disengage Procedure​

Motor and Brake Disassembly​

Motor Disassembly​

Drive Motor Removal​

Main Gearbox Disassembly​

Input Carrier Disassembly​

Hub Disassembly​

Spindle Disassembly​

Spindle Sub-Assembly​

Hub Sub-Assembly​

Input Carrier Sub-Assembly​

Main Gearbox Assembly​

Motor and Brake Assembly​

Motor Assembly​

Motor Assembly​

Tightening and Torquing Bolts​

Assembly Tools​

3.5 Electric Drive Motor​

Disassembly​

Replacing Motor Bearing​

Inspecting Motor Brushes​

Replacing Motor Brushes​

Replacing the Motor Cable​

Reassembling the Motor​

Motor Maintenance​

Disassembly​

Inspection and Service​

Reassembly​

3.6 Electric Drive Motor​

Drive Motor Troubleshooting​

Drive Motor Disassembly​

Drive Motor Inspection and Service​

Drive Motor Reassembly​

Drive Motor Servicing Guidelines​

3.7 Drive Motor Electrical Evaluation​

Servicing Guidelines​

Common Traction System Difficulties​

3.8 Power Module - Sevcon​

Power Module Electrical Evaluation​

3.9 Power Module - ZAPI​

ZAPI Power Module Electrical Evaluation​

3.10 Battery Removal​

Battery Maintenance and Safety Practices​

3.11 Battery Charger​

Battery Charger Maintenance​

Battery Charger Troubleshooting​

3.12 Battery Charger/Inverter (Option)​

Battery Charger/Inverter Troubleshooting​

3.13 Drive Motor Cable Routing​

3.14 Pothole Switch Replacement​

Rotary Angle Sensor Replacement​

3.15 Ground Control Station​

Printed Circuit Board (PCB) Replacement​

Tilt Sensor Replacement​

3.16 Arms and Platform Positioning and Support​

3.17 Platform Removal​

3.18 Scissor Arms Removal​

3.19 Platform Control Station​

Joystick Controller​

Section 4. Hydraulics​

4.1 Cylinders - Theory of Operation​

4.2 Valves - Theory of Operation​

Solenoid Control Valves (Bang-Bang)​

Relief Valves​

Crossover Relief Valves​

Proportional Valve​

Manual Descent Valve​

4.3 Cylinder Checking Procedure​

Cylinders Without Counterbalance Valves and Steer Cylinder​

4.4 Lift Pressure Setting Procedure​

4.5 Hydraulic Oil Fill​

Oil Check Procedure​

Slide Block Lubrication​

4.6 Lift Cylinder Removal​

4.7 Pump/Motor​

Pump Motor Electrical Evaluation​

Pump Removal​

Motor Removal​

4.8 Cylinder Repair​

Disassembly​

Steer Cylinder Piston Removal - Cyl. p/n- 1684456​

Cleaning and Inspection​

Assembly​

Section 5. JLG Control System​

5.1 Hand Held Analyzer​

To Connect the Hand Held Analyzer:​

Using the Analyzer:​

Changing the Access Level of the Hand Held Analyzer:​

Adjusting Parameters Using the Hand Held Analyzer​

Machine Setup​

5.2 Tilt Sensor Calibration​

Ground Module Software Version 1.5​

Ground Module Software Version 1.4​

Failure Troubleshooting for The Field​

5.3 Tilt Sensor Electrical Evaluation​

5.4 Elevation Angle Sensor Electrical Evaluation​

Tilt vs. Allowed Height Evaluation​

5.5 Elevation Sensor Calibration​

5.6 Updating Software​

5.7 Troubleshooting​

Analyzer Flow Chart​

5.8 Machine Model Adjustment - SEVCON - 1600346 Power Module​

5.9 Machine Model Adjustment - ZAPI - 1001092456 Power Module​

5.10 Machine Configuration Programming Information - SEVCON - 1600346​

5.11 Machine Configuration Programming Information - ZAPI - 1001092456​

Section 6. Diagnostic Trouble Codes​

6.1 Introduction​

6.2 DTC Index​

6.3 DTC Check Tables​

0-0 Help Comments​

2-1 Power-Up​

2-2 Platform Controls​

2-3 Ground Controls​

2-5 Function Prevented​

3-1 Line Contactor Open Circuit​

3-2 Line Contactor Short Circuit​

3-3 Ground Output Driver​

4-2 Thermal Limit (SOA)​

4-4 Battery Supply​

6-6 Communication​

6-7 Accessory​

7-7 Electric Motor​

8-1 Tilt Sensor​

8-2 Platform Load Sense​

9-9 Hardware​

Section 7. General Electrical Information & Schematics​

7.1 General​

7.2 Multimeter Basics​

Grounding​

Backprobing​

Min/Max​

Polarity​

Scale​

Continuity Measurement Over Long Distances​

Requirements:​

Procedure​

7.3 Applying Silicone Dielectric Compound To Amp Connectors​

Assembly​

Disassembly​

Wedge Lock​

Service - Voltage Reading​

7.4 Working With Deutsch Connectors​

DT/DTP Series Assembly​

DT/DTP Series Disassembly​

HD30/HDP20 Series Assembly​

HD30/HDP20 Series Disassembly​

7.5 Switches​

Basic check​

Limit Switches​

Automatic Switches​

Switch Wiring - Low Side, High Side​

7.6 Circuit Boards: Inputs and Outputs​

7.7 Electrical Schematics and Layouts​

Electrical Schematic - 1870164G - Sheet 1 of 2​

Electrical Schematic - 1870164G - Sheet 2 of 2​

Electrical Schematic - 1870205B - Sheet 1 of 2​

Electrical Schematic - 1870205B - Sheet 2 of 2​

Electrical Schematic - Sheet 1 of 2 (Machines with MDI)​

Electrical Schematic - Sheet 2 of 2 (Machines with MDI)​

Inverter/Charger Schematic​

Electrical Components - Sheet 1 of 2​

Electrical Components - Sheet 2 of 2​

Electrical Components - Sheet 1 of 2​

Electrical Components - Sheet 2 of 2​

Electrical Components - Sheet 1 of 2​

Electrical Components - Sheet 2 of 2​

Electrical Components - Sheet 1 of 2 (Machines with MDI)​

Electrical Components - Sheet 2 of 2 (Machines with MDI)​

7.8 Hydraulic Schematic​

Hydraulic Schematic - 2792599C​