Service and Maintenance Manual

Models
1532E3
1932E3
2033E3
2046E3
2646E3
2658E3
3120762
may 15, 2002

ANSI
 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

Relieve system pressure by cycling the applicable

A.A GENERAL
control several times with the engine stopped and
This section contains the general safety precautions ignition on, to direct any line pressure back into the
which must be observed during maintenance of the reservoir. Pressure feed lines to system components
aerial platform. It is of utmost importance that main- can then be disconnected with minimal fluid loss.
tenance personnel pay strict attention to these warn-
ings and precautions to avoid possible injury to
themselves or others, or damage to the equipment. A.C MAINTENANCE
A maintenance program must be followed to ensure
that the machine is safe to operate.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS
LISTED IN THIS SECTION MAY RESULT IN MACHINE
DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
MODIFICATION OF THE MACHINE WITHOUT CERTIFI- SAFETY VIOLATION.
CATION BY A RESPONSIBLE AUTHORITY THAT THE
MACHINE IS AT LEAST AS SAFE AS ORIGINALLY • NO SMOKING IS MANDATORY. NEVER REFUEL DUR-
MANUFACTURED, IS A SAFETY VIOLATION. ING ELECTRICAL STORMS. ENSURE THAT FUEL CAP
IS CLOSED AND SECURE AT ALL OTHER TIMES.
The specific precautions to be observed during • REMOVE ALL RINGS, WATCHES AND JEWELRY
maintenance are inserted at the appropriate point in WHEN PERFORMING ANY MAINTENANCE.
the manual. These precautions are, for the most • DO NOT WEAR LONG HAIR UNRESTRAINED, OR
part, those that apply when servicing hydraulic and LOOSE-FITTING CLOTHING AND NECKTIES WHICH
larger machine component parts. ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
Your safety, and that of others, is the first consider- • OBSERVE AND OBEY ALL WARNINGS AND CAU-
ation when engaging in the maintenance of equip- TIONS ON MACHINE AND IN SERVICE MANUAL.
ment. Always be conscious of weight. Never attempt
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
to move heavy parts without the aid of a mechanical
STANDING SURFACES AND HAND HOLDS.
device. Do not allow heavy objects to rest in an
unstable position. When raising a portion of the • USE CAUTION WHEN CHECKING A HOT, PRESSUR-
equipment, ensure that adequate support is pro- IZED COOLANT SYSTEM.
vided. • NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING,
OR BOOM SAFETY PROP HAS BEEN ENGAGED.
SINCE THE M ACHINE M ANUFA CTURER HAS NO • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
DIRECT CONTROL OVER THE FIELD INSPECTION PERFORMING ANY OTHER MAINTENANCE, SHUT
AND MAINTENANCE, SAFETY IN THIS AREA RESPON- OFF ALL POWER CONTROLS.
SIBILITY OF THE OWNER/OPERATOR.
• BATTERY SHOULD ALWAYS BE DISCONNECTED
DURING REPLACEMENT OF ELECTRICAL COMPO-
NENTS.
A.B HYDRAULIC SYSTEM SAFETY
• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
It should be noted that the machines hydraulic sys- MENTS STOWED IN THEIR PROPER PLACE.
tems operate at extremely high potentially danger- • USE ONLY APPROVED, NONFLAMMABLE CLEANING
ous pressures. Every effort should be made to SOLVENTS.
relieve any system pressure prior to disconnecting
or removing any portion of the system.

3120762 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISON LOG

January 1999 - Original Issue

March 16, 1999 - Revised

May 30, 2001 - Revised

December 14, 2001 - Revised

January 17, 2002 - Revised

May 15, 2002 - Revised

b – JLG Lift – 3120762

 TABLE OF CONTENTS

TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a
A.B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a
A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a
SECTION 1 - SPECIFICATIONS
1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.4 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.5 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.6 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.7 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.8 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.9 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
SECTION 2 - PROCEDURES
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.3 Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.4 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.5 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.6 Component Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.7 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.8 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.9 Arm Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.10 Lift Cylinder Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.11 Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.12 Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2.13 Brake Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
2.14 Steer Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
2.15 Tilt Switch Adjustment (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
2.16 Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
2.17 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
2.18 Drive Motor (Sauer Danfoss). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
2.19 Pothole Protection System Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2.20 JLG SMART System™ Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2.21 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
2.22 Machine Model Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
2.23 Machine Configuration Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
2.24 JLG SMART System™ Help Messages and Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
2.25 Analyzer Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33
2.26 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
SECTION 3 - TROUBLESHOOTING
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.4 JLG SMART System™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3120762 – JLG Lift – i

TABLE OF CONTENTS (Continued)

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-2. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
2-1. Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-2. Lift Cylinder Components Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-3. Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-4. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-5. Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-6. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-7. Oil-lite Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-8. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-9. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-10. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-11. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-12. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-13. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-14. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2-15. Brake Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
2-16. Steer Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
2-17. Tilt Switch Leveling - Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
2-18. Tilt Switch Leveling - Voltmeter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
2-19. Pressure Setting Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
2-20. Drive Motor (Sauer Danfoss). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
2-21. JLG SMART System™ Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2-22. Organizational Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
3-1. Hydraulic Schematic - (2033E3/2046E3/2646E3/2658E3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-2. Electrical Schematic - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-3. Electrical Schematic - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-4. Electrical Componants Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-5. Electrical Componants Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Lift Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-2 Machine Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-3 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-4 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-5 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-6 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-7 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
2-1 Cylinder Component Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2-2 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
2-3 Machine Model Default Settings Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
2-4 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
2-5 Help Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
2-6 JLG SMART System™ Help Messages & Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
2-7 Analyzer Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33
2-8 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40
3-1 Hydraulic System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

ii – JLG Lift – 3120762

 SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

Optional - 5.00 x 16.00 - Solid, Rib

1.1 CAPACITIES
Optional (2046E3/2646E3/2658E3) - 7.50 x 16.00 - Solid,
Hydraulic Oil Tank Flotation Tread
1532E3/1932E3 PARKING BRAKE - Single cylinder, spring applied,
hydraulically released
3.7 gallons (14.0 liters)
DRIVE MOTORS
2033E3/2046E3
1532E3/1932E3 - 9.9 in[3] (160 cm[3]) displacement
3.35 gallons (12.7 liters)
2033E3 - 14.0 in[3] (225 cm[3]) displacement
2646E3/2658E3
2046E3/2646E3/2658E3 - 16.2 in[3] (265 cm[3]) displace-
3.35 gallons (12.7 liters) ment

Hydraulic System (Including Tank) Hydraulic Filter - Inline

1532E3/1932E3 - Approximately 4.75 gallons (17 liters) Return - Bypass Type
2033E3/2046E3 - Approximately 5.25 gallons (20 liters) 10 Microns Nominal
2646E3/2658E3 - Approximately 5.75 gallons (22 liters)
Platform Size
1532E3/1932E3 - 30 in x 64 in (0.8 m x 1.6 m)
1.2 COMPONENT DATA
2033E3 - 30 in x 94 in (0.8 m x 2.4 m)
Hydraulic Pump/Electric Motor Assembly 2046E3/2646E3 - 42 in x 94 in (1.1 m x 2.4 m)
24 Volts DC motor w/single section gear pump 2658E3 - 54 in x 94 in (1.4 m x 2.4 m)
All models 3.0 gpm (11.4 lpm)

Battery Charger 1.3 PERFORMANCE DATA

20 Amp SCR Travel Speed
120/240 Volts AC - 50 Hz input 1532E3/1932E3.
24 Volts DC - 20 Amp output w/auto timer Low Speed - 1.3 mph (2.1 kmh)
Japanese Specification Elevated Speed - 0.5 mph (0.80 kmh)
100/200 Volts AC - 50/60 Hz input Maximum Speed - 2.3 mph (3.7 kmh)
24 Volts DC - 20 Amp output w/auto timer 2033E3.

Batteries (4) Low Speed - 1.5 mph (2.1 kmh)

All models - 6 Volt, 220 Amp Hour Elevated Speed - 0.5 mph (0.80 kmh)

Optional - (2033E3/2046E3/2646E3/2658E3) 6 Volt, 245 Maximum Speed - 2.4 mph (3.9 kmh)
Amp Hour 2046E3.

Steer/Drive System Low Speed - 1.3 mph (2.1 kmh)

TIRES - 1532E3/1932E3 Elevated Speed - 0.5 mph (0.80 kmh)
Standard - 4.50 x 14.00 - Solid, Non-Marking Maximum Speed - 2.4 mph (3.9 kmh)
Optional - 4.50 x 14.00 - Solid, Rib
TIRES - 2033E3/2046E3/2646E3/2658E3
Standard - 5.00 x 16.00 - Solid, Non-Marking

3120762 – JLG Lift – 1-1

 SECTION 1 - SPECIFICATIONS

2646E3/2658E3. NOTE: If machine is equipped with optional pipe racks, max-

imum load on pipe racks is 100 lb. (45 kg). Maximum
Low Speed - 1.3 mph (2.1 kmh)
total capacity of pipe racks and platform combined is
Elevated Speed - 0.5 mph (0.80 kmh) as follows:
Maximum Speed - 2.1 mph (3.4 kmh)
2033E3/2646E3 - 650 lb (295 kg)
Gradeability 2046E3/2658E3- 900 lb (408 kg)
All Models - 25%
Manual Platform Extension Capacity
Inside Turning Radius All Models - 250 lb. (120 kg) - 1 person
1532E3/1932E3/2033E3 - 2 in (5.1 cm)
Powered Deck Extension Capacity (Models
2046E3/2646E3/2658E3 - 16 in (40.6 cm)
2033E3, 2046E3, 2646E3, 2658E3 Only)
Inside Turning Angle 4 Ft (1.2 m) Extension
1532E3/1932E3/2033E3 - 87° 750 lb (340 kg) - 2 persons
2046E3/2646E3/2658E3 - 80° 6 Ft (1.8 m) Extension

Lift (No Load in Platform) 350 lb (159 kg) - 2 persons

Table 1-1. Lift Speeds FOR MODELS 2033E3, 2046E3, 2646E3, AND 2658E3 EQUIPPED
WITH EITHER THE 4 FT. (1.2 M) OR 6 FT. (1.8 M) POWERED DECK
MODEL LIFT UP (sec) LIFT DOWN (sec) EXTENSION, THE MAXIMUM TOTAL PLATFORM CAPACITY WITH
THE EXTENSION, EXTENDED OR RETRACTED, IS 750 LB. (340
1532E3 16-21 24-32 KG) - 2 PERSONS.
1932E3 17-22 24-32
Machine Weight
2033E3 33-38 30-35

2046E3 34-39 28-33 Table 1-2. Machine Weights

2646E3 48-53 30-35
MODEL DOMESTIC CSA
2658E3 59-69 30-35
1532E3 2630 lb 2630 lb
(1193 kg) (1193 kg)
Platform Capacity
1932E3 2900 lb 3050 lb
1532E3 - 600 lb (270 kg) (1315 kg) (1384kg)
1932E3 - 500 lb (230 kg)
2033E3 3700 lb 3700 lb
2033E3/2646E3 - Standard - 750 lb (340 kg) (1680 kg) (1680 kg)
2033E3/2646E3 - Optional - 1,000 lb (455 kg) 2046E3 3940 lb 3940 lb
2046E3/2658E3- 1,000 lb (455 kg) (1790 kg) (1790 kg)

2646E3 4370 lb 4370 lb

(1990 kg) (1990 kg)

2658E3 4680 lb 4680 lb

(2120 kg) (2120 kg)

Wheelbase
1532E3/1932E3 - 50.0 in (1.3 m)

2033E3/2046E3/2646E3/2658E3 - 73.0 in (1.9 m)

1-2 – JLG Lift – 3120762

 SECTION 1 - SPECIFICATIONS

Machine Height (Platform Fully Elevated) With Platform Elevated - (Pothole Protection System
Lowered)
1532E3 - 15 ft (4.6 m)
1932E3 - 19 ft (5.8 m) All Models - 0.75 in (1.9 cm)

2033E3/2046E3 - 20 ft (6.1 m)
Maximum Tire Load
2646E3/2658E3 - 26 ft (7.9 m)
1532E3 - 1,060 lb (481 kg)
Machine Height (Platform Lowered)
1932E3 - 1,100 lb (499 kg)
1532E3 - 75.75 in. (1.9 m).
2033E3 - 1,410 lb (640 kg)
1932E3 - 79.75 in. (2.0 m).
2033E3/2046E3 - 79.0 in. (2.0 m). 2046E3 - 1,710 lb (776 kg)

2646E3/2658E3 - 88.0 in. (2.2 m). 2646E3 - 1,750 lb (794 kg)

Platform Railing Height 2658E3 - 1,950 lb (885 kg)

Standard Handrails
Maximum Bearing Pressure
1532E3/1932E3/2033E3/2046E3 - 39.5 in (1.0 m)
2646E3/2658E3 - (Fold down rails standard) - 43.5 in (1.1 1523E3 - 92 psi (6.5 kg/cm2)
m)
1932E3 - 94 psi (6.6 kg/cm2)
Fold-Down Handrails
All Models - 43.5 in (1.1 m) 2033E3 - 102 psi (7.2 kg/cm2)

Machine Height (Platform Lowered - Fold 2046E3 - 117 psi (8.2 kg/cm2)
Downs Folded)
2646E3 - 119 psi (8.4 kg/cm2)
1532E3 - 72 in (1.8 m)
1932E3 - 76 in (1.9 m) 2658E3 - 130 psi (9.1 kg/cm2)

2033E3/2046E3 - 65.5 in (1.7 m)

2646E3/2658E3 - 74.5 in (1.9 m) 1.4 TORQUE REQUIREMENTS
Machine Length
1532E3/1932E3 - 71.25 in (1.8 m) Table 1-3. Torque Requirements

2033E3/2046E3/2646E3/2658E3 - 100 in (2.5 m) TORQUE VALUE

DESCRIPTION INTERVAL HOURS
(DRY)
Machine Width Wheel Lugs 105-120 ft lb 500
1532E3/1932E3 w/standard tires - 32.5 in (0.8 m) (147-168 Nm)
Wheel Hub to Drive 125-150 ft lb* 600
2033E3 w/standard tires - 33.0 in (0.8 m)
Motor (169-203 Nm)
2046E3/2646E3 w/standard tires - 46.0 in (1.2 m) Motor Controller 60 in lb At Controller
2658E3 w/standard tires - 58.0 in (1.5 m) Battery Terminal (7Nm) Replacement Only
Nuts
2046E3/2646E3/2658E3 w/optional flotation tires - 60.0 in
(1.5 m)
* Torque nut to 125-150 ft lbs (dry), then add extra torque
Ground Clearance to line up the slot with the hole in the shaft to install the
cotter pin.
With Platform Lowered.
NOTE: When maintenance becomes necessary or a fas-
1532E3/1932E3/2033E3 - 3.00 in (7.6 cm)
tener has loosened, refer to the Torque Chart to
2046E3/2646E3/2658E3 - 3.50 in (8.9 cm) determine proper torque value.

3120762 – JLG Lift – 1-3

 SECTION 1 - SPECIFICATIONS

NOTE: Aside from JLG recommendations, it is not advisable

1.5 LUBRICATION to mix oils of different brands or types, as they may
not contain the same required additives or be of
Hydraulic Oil comparable viscosities. If use of hydraulic oil other
than Mobilfluid 424 is desired, contact JLG Indus-
tries for proper recommendations.
Table 1-4. Hydraulic Oil
Lubrication Specifications
HYDRAULIC SYSTEM
OPERATING TEMPERATURE SAE VISCOSITY GRADE
RANGE Table 1-5. Lubrication Specifications
0° F to +23° F 10W
(-18° C to -5° C) KEY SPECIFICATIONS
0° F to +210° F 10W-20,10W-30
MPG Multipurpose Grease having a minimum dripping
(-18° C to +99° C) point of 350° F. Excellent water resistance and
50° F to +210° F 20W-20 adhesive qualities, and being of extreme pressure
(+10° C to +210° C) type. (Timken OK 40 pounds minimum)

EPGL Extreme Pressure Gear Lube (oil) meeting API ser-

NOTE: Hydraulic oils must have anti-wear qualities at least vice classification GL-5 or MIL-Spec MIL-L-2105
to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser- HO Hydraulic Oil. API service classification GL-3,
e.g.Mobilfluid 424 .
vice. JLG Industries recommends Mobilfluid 424
hydraulic oil, which has an SAE viscosity of 10W-30
and a viscosity index of 152.
1.6 SERIAL NUMBER LOCATIONS
NOTE: When temperatures remain consistently below 20° F For machine identification, a serial number plate is affixed
(-7° C) JLG recommends the use of Mobil DTE11 to the machine. The serial number plate is located on the
hydraulic oil. left rear side of the machine frame, just above the left rear
tire and wheel assembly. In addition, if the serial number
NOTE: Operate lift function through one complete cycle plate is damaged or missing, the machine serial number is
before checking oil level. Oil level should read at stamped on the right front of the frame. Cylinder Specifi-
full mark or within 1/2" below full cations.

Figure 1-1. Serial Number Location

1-4 – JLG Lift – 3120762

 SECTION 1 - SPECIFICATIONS

Drive Cut-Out (Models 2033E3, 2046E3,

1.7 CYLINDER SPECIFICATIONS
2646E3, and 2658E3 with Powered Deck
NOTE: All dimensions are given in inches (in), with the met- Extension)
ric equivalent, centimeters (cm), given in parenthe-
ses. On these machines, the Drive function is cut out when the
powered deck extension is extended with the platform
Table 1-6. Cylinder Specifications raised above the stowed position.

DESCRIPTION BORE STROKE ROD DIA

Electronic Armguard Switch
Lift Cylinder (1532E3/ 3.00 30.38 2.00
1932E3) (7.6) (77.2) (5.1) Lift down is cut out when the gap between the arms is in
Lift Cylinder (2033E3/ 3.50 48.19 2.00 the range of 5 in. to 8 in. (13 cm. to 20 cm.). This will cut
2046E3) (8.9) (122.40) (5.1) out lift down and sound the platform alarm for 1/2 second
on, 1/2 second off, and repeat this for three seconds. After
Lift Cylinder (2646E3/ 4.00 48.44 2.50
three seconds the operator must re-select the lift function
2658E3) (10.2) (123.0) (6.4)
and continue lifting down.
Steer Cylinder - All 1.50 6.35 0.75
Models (3.8) (15.9) (1.9)
Temperature Switch
Parking Brake Cylin- 2.00 1.75 1.00
der - All Models (5.1) (4.4) (2.5) This switch prevents the high drive function from engag-
ing when the oil temperature is very cold. The machine will
remain in low drive until the oil has warmed and will then
1.8 PRESSURE SETTINGS automatically move up to high drive.

Main Relief - 3000 psi + 50/- 0 psi (207 bar + 3.4/ - 0 bar).
Overload Protection (Japanese Specification
Steer Relief - 2100 psi (145 bar). Only)
Lift Up Relief. When the platform is loaded to 120% of its rated capacity,
the lift up and drive functions are cut out and the platform
1532E3 - 1625 psi (112 bar).
alarm (if equipped) is sounded for two seconds on, two
1932E3 - 2000 psi (138 bar). seconds off while the operator tries to activate either lift up
or drive. Remove weight from the platform to restore lift up
2033E3 - 1525 psi (105 bar). and drive functions operation and to silence the alarm (if
equipped).
2046E3 - 1800 psi (124 bar).

2646E3 - 1800 psi (124 bar).

2658E3 - 2100 psi (145 bar). 1.10 CRITICAL STABILITY WEIGHTS

Powered Deck Extension Relief (If Equipped)

Table 1-7. Critical Stability Weights
3000 psi (207 bar).
2033E3/2046E3/
Component 1532E3/1932E3
2646E3/2658E3
1.9 LIMIT SWITCHES Tires-Solid (each) 24 lb 31 lb
The machines are equipped with the following limit (11 kg) (14 kg)
switches: Tires-Solid-Non- 24 lb 30 lb
Marking (each) (11 kg) (14 kg)
Tilt Alarm (optional 1-1/2° or 2°) Motor/Pump 41 lb 41 lb
Illuminates a light on the platform and sounds an alarm Assembly (19 kg) (19 kg)
when the machine is 11/2° or 2°, depending on which tilt Batteries - Standard. 63 lb 63 lb
the machine is equipped with, out of level in any direction. (each) (21 kg) (21 kg)
Batteries - Standard 252 lb 252 lb
High Drive Cut-Out (combined) (114 kg) (114 kg)
High drive speed is cut out when the platform is raised
above the stowed position.

3120762 – JLG Lift – 1-5

 SECTION 1 - SPECIFICATIONS

Figure 1-2. Torque Chart

1-6 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

SECTION 2. PROCEDURES

items must be maintained on a scheduled basis in

2.1 GENERAL order to function properly.
This section provides information necessary to perform
2. At any time when air, fuel, or oil lines are discon-
maintenance on the scissor lift. Descriptions, techniques
nected, clear adjacent areas as well as the openings
and specific procedures are designed to provide the saf-
and fittings themselves. As soon as a line or compo-
est and most efficient maintenance for use by personnel
nent is disconnected, cap or cover all openings to
responsible for ensuring the correct installation and oper-
prevent entry of foreign matter.
ation of machine components and systems.
3. Clean and inspect all parts during servicing or main-
NOTE: Maintenance procedures provided in this section
tenance, and assure that all passages and openings
apply to all six scissor lift models covered in this
are unobstructed. Cover all parts to keep them
manual. Procedures that apply to a specific model
clean. Be sure all parts are clean before they are
will be so noted.
installed. New parts should remain in their contain-
ers until they are ready to be used.

Components Removal and Installation

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES
CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE
1. Use adjustable lifting devices, whenever possible, if
NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND
mechanical assistance is required. All slings (chains,
TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK
cables, etc.) should be parallel to each other and as
IS RESUMED.
near perpendicular as possible to top of part being
lifted.
The maintenance procedures included consist of servic-
ing and component removal and installation, disassembly 2. Should it be necessary to remove a component on
and assembly, inspection, lubrication and cleaning. Infor- an angle, keep in mind that the capacity of an eye-
mation on any special tools or test equipment is also pro- bolt or similar bracket lessens, as the angle between
vided where applicable. the supporting structure and the component
becomes less than 90°.
3. If a part resists removal, check to see whether all
2.2 SERVICING AND MAINTENANCE
nuts, bolts, cables, brackets, wiring, etc., have been
GUIDELINES removed and that no adjacent parts are interfering.

General Component Disassembly and Reassembly

The following information is provided to assist you in the When disassembling or reassembling a component, com-
use and application of servicing and maintenance proce- plete the procedural steps in sequence. Do not partially
dures contained in this chapter. disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been
Safety and Workmanship overlooked. Do not make any adjustments, other than
Your safety, and that of others, is the first consideration those recommended, without obtaining proper approval.
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy Pressure-Fit Parts
parts without the aid of a mechanical device. Do not allow When assembling pressure-fit parts, use an “anti-seize” or
heavy objects to rest in an unstable position. When raising molybdenum disulfide base compound to lubricate the
a portion of the equipment, ensure that adequate support mating surface.
is provided.
Bearings
Cleanliness
1. When a bearing is removed, cover it to keep out dirt
1. The most important single item in preserving the
and abrasives. Clean bearings in nonflammable
long service life of a machine is to keep dirt and for-
cleaning solvent and allow to drip dry. Compressed
eign materials out of the vital components. Precau-
air can be used but do not spin the bearing.
tions have been taken to safeguard against this.
Shields, covers, seals, and filters are provided to 2. Discard bearings if the races and balls (or rollers)
keep air, fuel, and oil supplies clean; however, these are pitted, scored, or burned.

3120762 – JLG Lift – 2-1

 SECTION 2 - PROCEDURES

3. If a bearing is found to be serviceable, apply a light Batteries

coat of oil and wrap it in clean (waxed) paper. Do not
unwrap reusable or new bearings until they are Clean batteries, using a non-metallic brush and a solution
ready to install. of baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry batteries and coat terminals with
4. Lubricate new or used serviceable bearings before an anti-corrosion compound.
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bear- Lubrication and Servicing
ing is to be installed on a shaft, apply pressure to the
Components and assemblies requiring lubrication and
inner race.
servicing are shown in Section 1.
Gaskets
Check that holes in gaskets align with openings in the 2.3 LUBRICATION INFORMATION
mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or stock of equivalent material Hydraulic System
and thickness. Be sure to cut holes in the right location, as
blank gaskets can cause serious system damage. 1. The primary enemy of a hydraulic system is contam-
ination. Contaminants enter the system by various
Bolt Usage and Torque Application means, e.g., using inadequate hydraulic oil, allowing
moisture, grease, filings, sealing components, sand,
1. Use bolts of proper length. A bolt which is too long etc., to enter when performing maintenance, or by
will bottom before the head is tight against its related permitting the pump to cavitate due to insufficient
part. If a bolt is too short, there will not be enough system warm-up or leaks in the pump supply (suc-
thread area to engage and hold the part properly. tion) lines.
When replacing bolts, use only those having the
2. The design and manufacturing tolerances of the
same specifications of the original, or one which is
component working parts are very close, therefore,
equivalent.
even the smallest amount of dirt or foreign matter
2. Unless specific torque requirements are given within entering a system can cause wear or damage to the
the text, standard torque values should be used on components and generally results in faulty opera-
heat-treated bolts, studs, and steel nuts, in accor- tion. Every precaution must be taken to keep
dance with recommended shop practices. hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the speci-
Hydraulic Lines and Electrical Wiring
fied intervals required in Section 1. Always examine
Clearly mark or tag hydraulic lines and electrical wiring, as filters for evidence of metal particles.
well as their receptacles, when disconnecting or removing
them from the unit. This will assure that they are correctly 3. Cloudy oils indicate a high moisture content which
reinstalled. permits organic growth, resulting in oxidation or cor-
rosion. If this condition occurs, the system must be
drained, flushed, and refilled with clean oil.
Hydraulic System
4. It is not advisable to mix oils of different brands or
1. Keep the system clean. If evidence of metal or rub- types, except as recommended, as they may not
ber particles is found in the hydraulic system, drain contain the same required additives or be of compa-
and flush the entire system. rable viscosities. Good grade mineral oils, with vis-
cosities suited to the ambient temperatures in which
2. Disassemble and reassemble parts on clean work the machine is operating, are recommended for use.
surface. Clean all metal parts with non-flammable
cleaning solvent. Lubricate components, as NOTE: Metal particles may appear in the oil or filters of new
required, to aid assembly. machines due to the wear-in of meshing compo-
nents.
Lubrication
Hydraulic Oil
Service applicable components with the amount, type,
and grade of lubricant recommended in this manual, at 1. Refer to Hydraulic Oil Table in previous section for
the specified intervals. When recommended lubricants are recommendations for viscosity ranges.
not available, consult your local supplier for an equivalent
that meets or exceeds the specifications listed.

2-2 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

2. JLG recommends Mobilfluid 424, which has an SAE Lubrication Specifications

viscosity of 10W-30 and a viscosity index of 152 or,
as an alternate, Kendall Hyken 052 hydraulic oil, Specified lubricants, as recommended by the component
which has an SAE viscosity of 10W-20 and a viscos- manufacturers, are always the best choice, however,
ity index of 152. Mobilfluid 424 and Kendall Hyken multi-purpose greases usually have the qualities which
052 are fully compatible, and can be mixed as nec- meet a variety of single purpose grease requirements.
essary. Should any question arise regarding the use of greases in
maintenance stock, consult your local supplier for evalua-
NOTE: Start-up of hydraulic system with oil temperatures
tion. Refer to the Lubrication Specifications Table in the
below -15 degrees F (-26 degrees C). is not recom-
previous section for an explanation of the lubricant key
mended. If it is necessary to start the system in a
designations appearing in the Lubrication Chart.
sub-zero environment, it will be necessary to heat
the oil with a low density, 100VAC heater to a mini-
mum temperature of -15 degrees F (-26 degrees C).
2.4 CYLINDERS - THEORY OF OPERATION
3. The only exception to the above is to drain and fill
the system with Mobil DTE 11 oil or its equivalent. Cylinders are of the double acting type. The Lift and Steer
This will allow start up at temperatures down to -20 systems incorporate double acting cylinders. A double
degrees F (-29 degrees C). However, use of this oil acting cylinder is one that requires oil flow to operate the
will give poor performance at temperatures above cylinder rod in both directions. Directing oil (by actuating
120 degrees F (49 degrees C). Systems using DTE the corresponding control valve to the piston side of the
11 oil should not be operated at temperatures above cylinder) forces the piston to travel toward the rod end of
200 degrees F (94 degrees C). under any condition. the barrel, extending the cylinder rod (piston attached to
rod). When the oil flow is stopped, movement of the rod
Changing Hydraulic Oil will stop. By directing oil to the rod side of the cylinder, the
piston will be forced in the opposite direction and the cyl-
1. Use of any of the recommended crankcase or inder rod will retract.
hydraulic oils increases JLG’s recommended oil
change interval to 1200 hours. However, filter ele- A holding valve is used in the Lift circuit to prevent retrac-
ments must be changed after the first 50 hours of tion of the cylinder rod should a hydraulic line rupture or a
operation and every 300 hours thereafter.When leak develop between the cylinder and its related control
changing the oil, use only those oils meeting or valve.
exceeding the specifications appearing in this man-
ual. If you are unable to obtain the same type of oil
supplied with the machine, consult your local sup-
plier for assistance in selecting the proper equiva- 2.5 VALVES - THEORY OF OPERATION
lent. Avoid mixing petroleum and synthetic base oils.
2. Use every precaution to keep the hydraulic oil clean.
Solenoid Control Valves (Bang-Bang)
If the oil must be poured from the original container Control valves used are four-way three-position solenoid
into another, be sure to clean all possible contami-
valves of the sliding spool design. When a circuit is acti-
nants from the service container. Always clean the
vated and the control valve solenoid energizes, the spool
mesh element of the filter and replace the cartridge
is shifted and the corresponding work port opens to per-
any time the system oil is changed.
mit oil flow to the component in the selected circuit, with
3. While the unit is shut down, a good preventive main- the opposite work port opening to reservoir. Once the cir-
tenance measure is to make a thorough inspection cuit is deactivated (control returned to neutral), the valve
of all hydraulic components, lines, fittings, etc., as spool returns to neutral (center) and oil flow is then
well as a functional check of each system, before directed through the valve body and returns to reservoir. A
placing the machine back in service. typical control valve consists of the valve body, sliding
spool, and two solenoid assemblies. The spool is
machine fitted in the bore of the valve body. Lands on the
spool divide the bore into various chambers, which, when
the spool is shifted, align with corresponding ports in the
valve body open to common flow. At the same time other
ports would be blocked to flow. The spool is spring-
loaded to center position, therefore when the control is
released, the spool automatically returns to neutral, pro-
hibiting any flow through the circuit.

3120762 – JLG Lift – 2-3

 SECTION 2 - PROCEDURES

Proportional Control Valves Lift Cylinder Counterbalance/Manual

Descent Valve
The proportional control valves provide a power output
matching that required by the load. A small line connected The lift cylinder counterbalance/manual descent valve is
to a load sensing port feeds load pressure back to a located on top of the lift cylinder. The counterbalance
sequence valve. The sequence valve senses the differ- valve is used to hold the platform in place when raised. A
ence between the load and pump outlet pressure, and cable is connected to the valve which, when pulled, manu-
varies the pump displacement to keep the difference con- ally opens the lift down port and allows the platform to be
stant. This differential pressure is applied across the lowered in the event hydraulic power is lost.
valve’s meter-in spool, with the effect that pump flow is
determined by the degree of spool opening, independent Positive Traction Valve
of load pressure. Return lines are connected together,
simplifying routing of return flow and to help reduce cavi- The positive traction solenoid valve is located on the main
tation. Load sensing lines connect through shuttle valves control valve and is activated by a switch on the platform
to feed the highest load signal back to the sequence control box. When activated, it equally divides the flow of
valve. Integral actuator port relief valves, anti-cavitation hydraulic oil in the drive circuit to send an equal amount of
check valves, and load check valves are standard. oil to each drive motor.

Relief Valves
2.7 WEAR PADS
Main relief valves are installed at various points within the
hydraulic system to protect associated systems and com- Sliding Pads
ponents against excessive pressure. Excessive pressure
can be developed when a cylinder reaches its limit of The original thickness of the sliding pads is 2.0 inches (51
travel and the flow of pressurized fluid continues from the mm). Replace sliding pads when worn to 1.875 inches (48
system control. The relief valve provides an alternate path mm).
for the continuing flow from the pump, thus preventing
rupture of the cylinder, hydraulic line or fitting. Complete
failure of the system pump is also avoided by relieving cir- 2.8 CYLINDER CHECKING PROCEDURES
cuit pressure. The relief valve is installed in the circuit
between the pump outlet (pressure line) and the cylinder NOTE: Cylinder checks must be performed any time a cylin-
of the circuit, generally as an integral part of the system der component is replaced or when improper system
valve bank. Relief pressures are set slightly higher than operation is suspected.
the load requirement, with the valve diverting excess
pump delivery back to the reservoir when operating pres- Cylinder w/o Counterbalance Valves -
sure of the component is reached. Platform Extension Cylinder (If Equipped),
Brake Cylinder and Steer Cylinder
Crossover Relief Valves
Crossover relief valves are used in circuits where the actu-
ator requires an operating pressure lower than that sup- OPERATE FUNCTIONS FROM GROUND CONTROL STATION
plied to the system. When the circuit is activated and the ONLY.
required pressure at the actuator is developed, the cross-
over relief diverts excess pump flow to the reservoir. Indi-
vidual, integral reliefs are provided for each side of the
circuit. WHEN WORKING ON THE LIFT CYLINDER, RAISE THE PLAT-
FORM COMPLETELY AND SUPPORT THE PLATFORM USING A
SUITABLE OVERHEAD LIFTING DEVICE.
2.6 COMPONENT FUNCTIONAL DO NOT FU LLY EXTEN D CYLINDER TO END OF STROKE.
DESCRIPTION RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES-
SURE.

Hydraulic Pump 1. Using all applicable safety precautions, activate

The main hydraulic pump is an integral part of the electric motor and fully extend cylinder to be checked. Shut
motor/pump assembly, located at the rear of the battery down motor.
and ground control tray on the frame of the machine. The
pump is a two-section pump that provides an output of
3.13 gpm (11.8 lpm) from each pump section.

2-4 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

2. Carefully disconnect hydraulic hose from retract port 4. There will be initial weeping of hydraulic fluid, which
of cylinder. There will be initial weeping of hydraulic can be caught in a suitable container. After the initial
fluid which can be caught in a suitable container. discharge, there should not be any further leakage
After the initial discharge, there should be no further from the ports. If leakage continues at a rate of 6-8
leakage from the retract port. drops per minute or more, the counterbalance valve
is defective and must be replaced.
3. Activate motor and activate cylinder extend function.
Check retract port for leakage. 5. If no repairs are necessary or when repairs have
been made, carefully reconnect hydraulic hoses to
4. If cylinder leakage is 6-8 drops per minute or more, the appropriate ports.
piston seals are defective and must be replaced. If
cylinder retract port leakage is less than 6-8 drops 6. Remove lifting device from platform, activate hydrau-
per minute, carefully reconnect hose to retract port lic system and run cylinder through one complete
and retract cylinder. cycle to check for leaks.

5. With cylinder fully retracted, shut down motor and

carefully disconnect hydraulic hose from cylinder 2.9 ARM ASSEMBLY MAINTENANCE
extend port.

6. Activate motor and activate cylinder retract function.

Check extend port for leakage. IT IS RECOMMENDED THAT WHEN PERFORMING MAINTENANCE
ON THE ARM ASSEMBLY THE MACHINE BE PARKED IN THE
7. If cylinder leakage is 6-8 drops per minute or more, STOWED POSITION (FULLY LOWERED).
piston seals are defective and must be replaced. If
extend port leakage is less than 6-8 drops per Platform Removal
minute, carefully reconnect hose to extend port,
then activate cylinder through one complete cycle Remove the platform from the arm assembly, with the plat-
and check for leaks. form extension and rail assemblies intact, as follows:

1. Disconnect electrical control cable from platform

Cylinders w/Single Counterbalance Valves - control box.
Lift Cylinder
2. Disconnect any other options that lead to the plat-
form from the arm assembly

NOTE: The approximate weight of the platform and rail

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
assemblies is 500 lb (227 kg). When removing the
ONLY. platform and rail assemblies, be sure the lifting
device being used is capable of handling these
1. Using all applicable safety precautions, activate weights.
hydraulic system.
3. Using an overhead crane, or suitable lifting device,
use nylon straps to support platform and rail assem-
blies.
WHEN WORKING ON THE LIFT CYLINDER, RAISE THE PLAT-
FORM COMPLETELY AND SUPPORT THE PLATFORM USING A 4. Remove pin retaining hardware from front and rear
SUITABLE OVERHEAD LIFTING DEVICE. deck pins.
DO NOT FULLY EXTEND LIFT CYLINDER TO END OF STROKE.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES- 5. Using a suitable brass drift and a hammer, remove
SURE. pins from the pivot mounts on the under side front of
the platform and from the slide blocks in rear.
2. Raise platform completely then retract cylinder
6. Using all applicable safety precautions, carefully lift
slightly to avoid trapping pressure. Place a suitable platform and rail assemblies clear of arm assembly
overhead lifting device approximately 1 inch (2.5 and lower to ground or suitable supported work sur-
cm) below the platform. face.
3. Shut down hydraulic system and allow machine to
sit for 10-15 minutes. Carefully remove hydraulic
hoses from cylinder port block.

3120762 – JLG Lift – 2-5

 SECTION 2 - PROCEDURES

2. Remove the bolt and locknut securing the cylinder

rod attach pin to the upper inner arm assembly.
Using a suitable brass drift, drive out the rod end
attach pin from the arm assembly.

3. Retract the lift cylinder rod completely.

4. Tag and disconnect the hydraulic lines, then cap the

lift cylinder hydraulic lines and ports.

5. Remove the bolt and locknut securing the barrel end

attach pin to the lower arm assembly. Using a suit-
able brass drift, drive out the barrel end attach pin
from the arm assembly.

6. Carefully remove the cylinder from the scissor lift

and place in a suitable work area.

Lift Cylinder Installation

1. Install lift cylinder in place using suitable slings,

aligning barrel end attach pin mounting holes on
lower arm assembly.
Figure 2-1. Platform Removal
2. Using a suitable drift, drive the barrel end attach pin
through the mounting holes in the lift cylinder and
Disassembly of Arms
the lower arm assembly. Secure in place with the
bolt and locknut.
NOTE: If performing maintenance on any of the arms or arm
bushings be sure and pull the pins outward. DO NOT 3. Remove cylinder port plugs and hydraulic line caps
try to drive the pins through or they will fall into the and correctly attach lines to cylinder ports.
cross tubes of the inner arms.
4. Extend the cylinder rod until the attach pin hole
1. Remove hardware, from the pin, that secures the pin aligns with those in the upper arm assembly. Using a
to the arm. suitable drift, drive the cylinder rod attach pin
through the aligned holes, taking care to align the
2. Place a pry bar or suitable prying device behind the pin retaining hole with the hole in arm assembly.
washer and retaining ring and pull the arm pin out. Secure the pin in place with the bolt and locknut.

3. Using a suitable lifting device, lift the arm to be 5. Lower platform to stowed position and shut down
removed and lower to the ground or suitable sup- motor. Check hydraulic fluid level and adjust accord-
ported work surface. ingly.

4. Repeat this, if necessary, in order to perform mainte-

nance on various arms.
2.11 LIFT CYLINDER REPAIR
NOTE: If the removal of the lift cylinder becomes necessary
refer to lift cylinder removal section, steps 2 through NOTE: The following procedures apply to the lift cylinder
6. only.

Disassembly
2.10 LIFT CYLINDER REMOVAL AND
INSTALLATION
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON
Lift Cylinder Removal A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. BE
SURE TO CLEAN ALL DIRT OR OTHER FOREIGN SUBSTANCES
1. Place the machine on a flat and level surface. Start FROM CYLINDER OPENINGS - PARTICULARY AT THE HEAD.
the motor and raise the platform. Shut down the
engine and attach a suitable lifting device to the plat- 1. Connect a suitable auxiliary hydraulic power source
form. to the cylinder port block fitting.

2-6 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

Figure 2-2. Lift Cylinder Components Assembly

DO NOT FU LLY EXTEN D CYLINDER TO END OF STROKE.

RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES-
SURE.

2. Operate the hydraulic power source and extend the

cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if nec-
essary.

3. If applicable, remove the cartridge-type holding

valve and fittings from the cylinder port block. Dis-
card o-rings.
Figure 2-3. Barrel Support
4. Place the cylinder barrel into a suitable holding fix-
ture. 7. Attach a suitable pulling device to the cylinder rod
port block or cylinder rod end, as applicable.
5. To aid in realignment, mark cylinder head and barrel
with a center punch.

6. Using a suitable spanner wrench, loosen the span-

ner nut retainer and remove the spanner nut from
the cylinder barrel.

3120762 – JLG Lift – 2-7

 SECTION 2 - PROCEDURES

Figure 2-6. Tapered Bushing Removal

Figure 2-4. Capscrew Removal
13. Screw the piston counter-clockwise, by hand, and
remove the piston from the cylinder rod.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL- 14. Remove and discard the piston o-rings, back-up
INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF- rings, guidelock rings and hydrolock seals.
CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND 15. If applicable, remove the piston spacer from the rod.
CYLINDER BARREL SURFACES.
16. Remove the rod from the holding fixture. Remove
the cylinder head and retainer plate from the rod.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning
solvent.
2. Inspect the cylinder rod for scoring, tapering, ovality,
or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for damage. Dress
threads as necessary.

Figure 2-5. Rod Support 4. Inspect inner surface of cylinder barrel tube for scor-
ing or other damage. Check inside diameter for
tapering or ovality. Replace if necessary.
8. With the barrel clamped securely, apply pressure to
the rod pulling device and carefully withdraw the 5. Inspect threaded portion of barrel for damage. Dress
complete rod assembly from the cylinder barrel. threads as necessary.

9. Using suitable protection, clamp the cylinder rod in 6. Inspect piston surface for damage and scoring and
a vise or similar holding fixture as close to the piston for distortion. Dress piston surface or replace piston
as possible. as necessary.
7. Inspect threaded portion of piston for damage.
10. If applicable, loosen and remove the nut which
dress threads as necessary.
attaches the piston to the rod, then remove the pis-
ton from the rod. 8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as nec-
11. If applicable, loosen and remove the cap screw(s)
essary.
securing the tapered bushing to the piston.
9. Inspect cylinder head inside diameter for scoring or
12. Insert the capscrew(s) in the threaded holes in the
other damage and for ovality and tapering. Replace
outer piece of the tapered bushing. Progressively
as necessary.
tighten the cap screw(s) until the bushing is loose
on the piston, then remove the bushing from the pis- 10. Inspect threaded portion of head for damage. Dress
ton. threads as necessary.

2-8 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

11. Inspect seal and o-ring grooves in head for burrs 1. Using a special tool, pictured in the following illustra-
and sharp edges. Dress applicable surfaces as nec- tion, install a new rod seal into the applicable cylin-
essary. der head gland groove. Refer to the following
illustration for the proper tool size.
12. Inspect cylinder head outside diameter for scoring
or other damage and ovality and tapering. Replace
as necessary.

13. If applicable, inspect rod and barrel bearings for

signs of correct lubrication and excessive wear. If
necessary, replace bearings as follows:

a. Thoroughly clean steel bushing hole of burrs,

dirt, etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage.
If steel bushing is worn or damaged, rod or bar-
rel (as applicable) must be replaced.
Figure 2-8. Rod Seal Installation
c. Lubricate inside of steel bushing with WD-40
prior to bearing installation.
d. Using arbor of the correct size, carefully press
the bearing into the steel bushing. WHEN INSTALLING NEW “POLY-PAK” TYPE PISTON SEALS,
ENSURE SEALS ARE INSTALLED PROPERLY. (SEE FIGURE 2-13.)
NOTE: Install the cylinder pin into the OIl-lite bearing dry. FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLA-
Lubrication is not required with chrome pins and
TION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER
bearings.
CYLINDER OPERATION.

2. Using a soft mallet, tap a new wiper seal into the

applicable cylinder head gland groove. Install a new
wear ring into the applicable head gland groove.

Figure 2-7. Oil-lite Bearing Installation

14. Inspect travel limiting collar or spacer for burrs and

sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.
Figure 2-9. Wiper Seal Installation
15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.

16. Inspect the oil ports for blockage or the presence of 3. Place a new o-ring and back-up seal in the applica-
dirt or other foreign material. Repair as necessary. ble outside diameter groove of the cylinder head.

17. If applicable, inspect piston rings for cracks or other 4. Install a washer ring onto the rod, then carefully
damage. Replace as necessary. install the head gland on the rod, ensuring that the
wiper and rod seals are not damaged or dislodged.
Assembly Push the head along the rod to the rod end, as
applicable.
NOTE: Prior to cylinder assembly, ensure that the proper
cylinder seal kit is used. 5. Carefully slide the piston spacer onto the rod.

NOTE: Apply a light film of hydraulic oil to all components 6. If applicable, correctly place a new o-ring and back-
prior to assembly. up rings in the inner piston diameter groove.

3120762 – JLG Lift – 2-9

 SECTION 2 - PROCEDURES

Figure 2-10. Installation of Head Seal Kit

Figure 2-12. Tapered Bushing Installation

7. Using suitable protection, clamp the cylinder rod in

a vise or similar holding fixture as close to the piston 11. Remove the cylinder rod from the holding fixture.
as possible.
12. Place new guidelock and hydrolock seals in the
8. Carefully thread the piston on the cylinder rod hand applicable outside diameter grooves of both the pis-
tight, ensuring that the o-ring and back-up rings are ton and the cylinder head.
not damaged or dislodged.
13. Position the cylinder barrel in a suitable holding fix-
9. Thread the piston onto the rod until it abuts the ture.
spacer end and install the tapered bushing.

NOTE: When installing the tapered bushing, the piston and

mating end of the rod must be free of oil.

Figure 2-13. Poly-Pak Piston Seal Installation

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE

CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
Figure 2-11. Piston Seal Kit Installation AND CYLINDER BARREL SURFACES.

14. With the barrel clamped securely, and while ade-

quately supporting the rod, insert the piston end into
the cylinder barrel. Ensure that the piston loading o-
ring and seal ring are not damaged or dislodged.
WHEN REBUILDING THE LIFT CYLINDER, APPLY LOCTITE #242
TO TA P E R E D B U S H I N G B O LT S , T H E N T I G H T E N B O LT S 15. Continue pushing the rod into the barrel until the cyl-
SECURELY. REFER TO TABLE 2-1, CYLINDER COMPONENT inder head gland can be inserted into the cylinder
TORQUE SPECIFICATIONS FOR PROPER BOLT TORQUE VAL- barrel.
UES.
16. Secure the cylinder head gland using the washer
10. Install the bolts into the bushing using Loctite #242. ring and socket head bolts. Refer to Table 2-1, Cylin-
Refer to Cylinder Component Torque Specifications der Component Torque Specifications for proper
Table for proper bolt torque values. bolt torque specifications.

2-10 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

2. Operate the hydraulic power source and extend the

cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if appli-
cable.
3. Remove the cartridge-type holding valve and fittings
from the cylinder port block. Discard o-rings.
4. Place the cylinder barrel into a suitable holding fix-
ture.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-

INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
Figure 2-14. Rod Assembly Installation CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.
17. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted) prior 5. Using a suitable spanner wrench inserted in the
to the reinstallation of any holding valve or valves. holes provided, turn the cylinder head counter-
clockwise to remove it from the cylinder barrel. If the
18. If applicable, install the cartridge-type holding valve head is difficult to turn or moves erratically, tap the
and fittings in the port block using new o-rings as tube adjacent to the head with a brass or plastic
applicable. mallet while turning it.

Table 2-1. Cylinder Component Torque Specifications 6. Attach a suitable pulling device to the cylinder rod
end.
Component Torque Value (w/Loctite)
7. With the barrel clamped securely, apply pressure to
Tapered Bushing Retaining 80 ft lb the rod pulling device and carefully withdraw the
Screws - Lift Cylinder (108 Nm) complete rod assembly from the cylinder barrel.
8. Using suitable protection, clamp the cylinder rod in
Head Retaining Screws 9 ft lb
a vise or similar holding fixture as close to the piston
(12 Nm)
and head as possible.
Piston Nut - 1532E3/1932E3 375-450 lb 9. Remove the lock nut which attaches the piston to
(508-610Nm) the rod, and remove the piston.
Piston Nut - 2033E3/2046E3/ 800-1000 ft lb 10. Slide the head off the rod from the piston end.
2646E3/2658E3 (1085-1356 Nm)
11. Remove and discard the sealing o-ring, wiper, u-cup
seal, static o-ring, static back-up ring and wear ring.

2.12 LIFT CYLINDER REPAIR 12. Remove the piston guidelock ring.
13. Remove and discard the piston o-ring and seals,
Disassembly then remove the piston spacer.
14. Remove the rod from the holding fixture. Remove
the cylinder head gland and retainer, if applicable.
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON Discard the o-rings, back-up rings, rod seals, and
A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. BE wiper seals.
SURE TO CLEAN ALL DIRT OR OTHER FOREIGN SUBSTANCES
FROM CYLINDER OPENINGS - PARTICULARY AT THE HEAD. Cleaning and Inspection
1. Connect a suitable auxiliary hydraulic power source 1. Clean all parts thoroughly in an approved cleaning
to the cylinder port block fitting. solvent.
2. Inspect the cylinder rod for scratches or pits deep
enough to catch the fingernail. Pits that go to the
DO NOT FU LLY EXTEN D CYLINDER TO END OF STROKE. base metal are unacceptable. Scratches that catch
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES- the fingernail but are not to the base metal, less than
SURE. 0.5 inch (12.7 mm) long and primarily in the circum-

3120762 – JLG Lift – 2-11

 SECTION 2 - PROCEDURES

ferential direction are acceptable provided they can- Assembly

not cut the rod seal. Chrome should be present over
the entire surface of the rod; the lack of chrome on NOTE: Prior to cylinder assembly, ensure that the proper
the rod surface is unacceptable. If an unacceptable cylinder seal kit is used. Refer to the Illustrated Parts
condition exists, repair or replace the rod. Manual.

3. Inspect the threaded portion of the rod for excessive NOTE: Apply a light film of hydraulic oil to all components
damage. Dress the threads as necessary. prior to assembly.

4. Inspect inner surface of cylinder barrel tube for

scratches and pits. There should be no scratches or
pits deep enough to catch the fingernail. Scratches WHEN INSTALLING NEW “POLY-PAK” TYPE PISTON SEALS,
that catch the fingernail but are less than 0.5 inch ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO FIGURE
(12.7 mm) long and primarily in the circumferential 2-7 FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
direction are acceptable provided they cannot cut INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
the piston seal. IMPROPER CYLINDER OPERATION.

5. Inspect the threaded portion of the barrel tube for 1. Using round-nose pliers or special installation tools,
damage. Dress the threads as necessary. twist the loaded u-cup seal into a “C” shape and
allow it to snap into the groove. Use a similar tech-
6. Inspect piston outside surface for scratches or pol- nique for installing the wiper.
ishing. Deep scratches are unacceptable. Polishing
2. Install a new static o-ring and back-up o-ring into the
indicates uneven loading and when this occurs, the
static seal groove, verifying that the back-up o-ring is
diameter should be checked for out-of-roundness. If
closest to the threads. Install a new sealing o-ring
out-of-roundness exceeds 0.007 inch (0.178 mm),
into the groove between the threads and the flange
this is unacceptable. Check the condition of the seal lip. Install a new wear ring into the inside applicable
and o-ring, looking particularly for metallic particles head groove. If possible, the head/seal assembly
embedded in the seal and o-ring surfaces. Remove should sit for at least one hour to allow the seals to
the seal and o-ring. Damage to the seal grooves, elastically restore.
particularly on the sealing surfaces, is unacceptable.
If an unacceptable condition exists, replace the pis- 3. Carefully slide the head assembly onto the cylinder
ton. rod, ensuring that the wiper seal, o-ring and wear
ring are not damaged or dislodged.
7. Inspect the piston spacer for burrs and sharp edges. 4. Carefully slide the piston spacer on the rod. If appli-
If necessary, dress inside diameter surface with cable, align the oil holes in the rod and the spacer.
Scotch Brite or equivalent. Secure the spacer, if applicable.
8. Inspect the cylinder head inside bore for scratches 5. Place a new o-ring in the inner piston diameter
or polishing. Deep scratches are unacceptable. Pol- groove.
ishing indicates uneven loading and when this
6. Carefully place the piston on the cylinder rod, ensur-
occurs, the bore should be checked for out-of-
ing that the o-ring is not damaged or dislodged.
roundness. If out-of-roundness exceeds 0.007 inch
(0.178 mm), this is unacceptable. Check for the con- 7. Using suitable protection, clamp the cylinder rod in
dition of the dynamic seals, looking particularly for a vise or similar holding fixture as close to the piston
metallic particles embedded in the seal surface. It is as possible.
normal to cut the static seal on the retaining ring
8. Push the piston onto the rod until it abuts the spacer
groove upon disassembly. Remove the rod seal, end and install the attaching nut.
static o-ring, backup ring, and rod wiper. Damage to
the seal grooves, particularly on the sealing sur-
faces, is unacceptable. If an unacceptable condition
exists, replace the head. APPLY “LOCQUIC PRIMER T” AND LOCTITE #242 TO PISTON
NUT THREADS, THEN TIGHTEN NUT TO TORQUE SHOWN IN
9. Inspect the port block fittings and holding valve. TABLE 2-1, CYLINDER COMPONENT TORQUE SPECIFICATIONS.
Replace as necessary.
9. Torque the piston nut to the proper torque as out-
10. Inspect the oil ports for blockage or the presence of lined in Table 2-1, Cylinder Component Torque
dirt or other foreign material. Repair as necessary. Specifications

2-12 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

10. Remove the cylinder rod from the holding fixture. 3. Using a suitable pair of snap ring pliers, carefully
remove the retaining ring from the cylinder barrel.
11. Install new seals and a new guidelock ring in the
applicable outside diameter grooves of the piston. 4. Attach a suitable pulling device to the cylinder rod
end.
12. Position the cylinder barrel in a suitable holding fix-
ture.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE INDER ROD, GUIDE, AND PISTON. AVOID PULLING THE ROD
CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
AND CYLINDER BARREL SURFACES.
5. With the barrel clamped securely, apply pressure to
13. With barrel clamped securely, and while adequately the rod pulling device and carefully withdraw the
supporting the rod, insert the piston end of the rod complete rod assembly from the cylinder barrel.
into the cylinder barrel. Ensure that the piston seals
6. Using suitable protection, clamp the cylinder rod in
are not damaged or dislodged.
a vise or similar holding fixture.
14. Continue pushing the rod into the barrel until the cyl-
7. Carefully remove the piston locknut and piston from
inder head can be inserted into the cylinder barrel.
the cylinder rod. Remove and discard the piston ring
15. Slide the head into the barrel and engage the and o-rings.
threads. Turn the head counterclockwise until the
first thread just passes the engagement point (the 8. Carefully remove the guide from the cylinder rod.
head will move noticeably), then turn the head Remove and discard the o-ring, back-up ring, rod
clockwise until it is hand-tight or fully seated. Insert a seal, and wiper ring.
spanner wrench into the holes provided and tighten
9. Remove the cylinder rod from the holding fixture.
1/8 to 1/4 turn past fully seated.

16. After the cylinder has been reassembled, the rod Cleaning and Inspection
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves. 1. Clean all parts thoroughly in an approved cleaning
17. If removed, install the cartridge-type holding valve solvent.
and fittings in the port block using new o-rings as 2. Inspect the cylinder rod for scoring, tapering, ovality,
applicable. Torque the holding valve cartridge to 50- or other damage. If necessary, dress rod with
55 ft lb (68-75 Nm). Scotch Brite or equivalent. Replace rod if necessary.

3. Inspect threaded portion of rod for excessive dam-

2.13 BRAKE CYLINDER REPAIR age. Dress threads as necessary.

4. Inspect inner surface of cylinder barrel tube for scor-

Disassembly
ing or other damage. Check inside diameter for
tapering or ovality. Replace if necessary.

5. Inspect piston surface for damage and scoring and

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON
for distortion. Dress piston surface or replace piston
A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
as necessary.
1. Tag and disconnect the hoses from the cylinder 6. Inspect seal and o-ring grooves in piston for burrs
ports. and sharp edges. Dress applicable surfaces as nec-
essary.

7. Inspect cylinder guide inside diameter for scoring or

DO NOT FU LLY EXTEN D CYLINDER TO END OF STROKE. other damage and for ovality and tapering. Replace
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES- as necessary.
SURE.
8. Inspect seal and o-ring grooves in guide for burrs
2. Place the cylinder barrel into a suitable holding fix- and sharp edges. Dress applicable surfaces as nec-
ture. essary.

3120762 – JLG Lift – 2-13

 SECTION 2 - PROCEDURES

Figure 2-15. Brake Cylinder Assembly

9. Inspect cylinder guide outside diameter for scoring 5. Carefully place the piston on the threaded end of the
or other damage and ovality and tapering. Replace cylinder rod, ensuring that the o-ring is not damaged
as necessary. or dislodged. Push the piston onto the rod as far as
it will go.
10. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary. 6. Install the piston locknut on the threaded end of the
cylinder rod and torque to 100-120 ft. lb. (136-163
Assembly Nm).

7. Remove the cylinder rod from the holding fixture.

NOTE: Prior to cylinder assembly, ensure that the proper
cylinder seal kit is used. 8. Position the cylinder barrel in a suitable holding fix-
ture.
NOTE: Apply a light film of hydraulic oil to all components
prior to assembly.

1. Using suitable protection, clamp the cylinder rod in EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
a vise or similar holding fixture. CYLINDER ROD, GUIDE, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
2. Place a new wiper ring, rod seal, o-ring, and back-up AND CYLINDER BARREL SURFACES.
ring into the applicable cylinder guide grooves.

3. Carefully install the guide on the rod, ensuring that 9. With the barrel clamped securely, and while ade-
the wiper ring and rod seal are not damaged or dis- quately supporting the cylinder rod, insert the piston
lodged. Push the guide onto the rod. end of the rod into the cylinder barrel. Ensure that
the piston ring and o-ring are not damaged or dis-
4. Place a new piston ring and o-rings on the piston. lodged.

2-14 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

10. Continue pushing the rod into the barrel until the cyl- 10. Carefully remove cylinder rod section one from cyl-
inder guide can be inserted into the cylinder barrel. inder rod section two and carefully remove the pis-
ton from the cylinder rod. Remove and discard the
11. Using all applicable safety precautions, secure the piston seal and o-ring.
cylinder rod assembly with a new retaining ring (12).
11. Carefully remove the guide from cylinder rod section
12. Reconnect the hydraulic hoses to the applicable cyl- one. Remove and discard the o-ring, back-up ring,
inder ports. rod seal, and wiper ring.
12. Remove the cylinder rod from the holding fixture.
2.14 STEER CYLINDER REPAIR
Cleaning and Inspection
Disassembly
1. Clean all parts thoroughly in an approved cleaning
solvent.
2. Inspect the cylinder rod for scoring, tapering, ovality,
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON
or other damage. If necessary, dress rod with
A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
Scotch Brite or equivalent. Replace rod if necessary.
1. Tag and disconnect the hoses from the cylinder 3. Inspect threaded portion of rod for excessive dam-
ports. age. Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scor-
ing or other damage. Check inside diameter for
DO NOT FU LLY EXTEN D CYLINDER TO END OF STROKE. tapering or ovality. Replace if necessary.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES-
5. Inspect piston surface for damage and scoring and
SURE.
for distortion. Dress piston surface or replace piston
as necessary.
2. Place the cylinder barrel into a suitable holding fix-
ture. 6. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as nec-
3. Using a suitable hammer, tap around the outside of
essary.
the cylinder barrel and guide to shatter the Loctite.
7. Inspect cylinder guide inside diameter for scoring or
4. Using a suitable spanner wrench, carefully remove
other damage and for ovality and tapering. Replace
the guide from the rod Clevis end of the cylinder bar-
as necessary.
rel.
8. Inspect seal and o-ring grooves in guide for burrs
5. Attach a suitable pulling device to the clevis end of and sharp edges. Dress applicable surfaces as nec-
cylinder rod section one. essary.
9. Inspect cylinder guide outside diameter for scoring
or other damage and ovality and tapering. Replace
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL- as necessary.
INDER ROD, GUIDE, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON 10. Inspect the oil ports for blockage or the presence of
AND CYLINDER BARREL SURFACES. dirt or other foreign material. Repair as necessary.

6. With the barrel clamped securely, apply pressure to Assembly

the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel. NOTE: Prior to cylinder assembly, ensure that the proper
7. Using a suitable hammer, tap around the outside of cylinder seal kit is used. Refer to the Illustrated Parts
the cylinder barrel and guide to shatter the Loctite. Manual.
Apply a light film of hydraulic oil to all components
8. Using a suitable spanner wrench, carefully remove prior to assembly.
the remaining guide from the cylinder barrel.
Remove and discard the wiper ring, rod seal, back- 1. Using suitable protection, clamp the cylinder rod
up ring and o-ring. section one in a vise or similar holding fixture.
9. Using suitable protection, clamp cylinder rod sec- 2. Place a new wiper ring, rod seal, o-ring, and back-up
tion two in a vise or similar holding fixture. ring into the cylinder rod guide grooves.

3120762 – JLG Lift – 2-15

 SECTION 2 - PROCEDURES

Figure 2-16. Steer Cylinder Repair

3. Carefully install the cylinder rod guide on rod section

one, ensuring that the wiper ring and rod seal are
not damaged or dislodged. Push the guide onto the EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
rod section. CYLINDER ROD, CYLINDER ROD GUIDE, AND PISTON. AVOID
PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAM-
4. Place a new piston ring on the piston and a new o-
AGE TO THE PISTON AND CYLINDER BARREL SURFACES.
ring on the threaded end of cylinder rod section two.
5. Carefully place the piston on the threaded end of 9. With the barrel clamped securely, and while ade-
cylinder rod section two, ensuring that the o-ring is quately supporting the cylinder rod assembly, insert
not damaged or dislodged. Push the piston onto the the piston end of the rod assembly into the cylinder
rod as far as it will go. barrel. Ensure that the piston ring and o-ring are not
6. Attach cylinder rod section one to the threaded end damaged or dislodged.
of cylinder rod section two and assemble.
10. Continue pushing the rod into the barrel until the cyl-
7. Remove the cylinder rod assembly from the holding inder rod guide can be inserted into the end of the
fixture. cylinder barrel.
8. Position the cylinder barrel in a suitable holding fix-
ture. 11. Coat the threads of the cylinder rod guide with Loc-
tite #242 then secure the cylinder rod guide to the
cylinder barrel using a suitable spanner wrench.

12. On the remaining cylinder rod guide place a new

wiper ring, rod seal, o-ring, and back-up ring into the
cylinder rod guide grooves.

2-16 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

13. Carefully install the cylinder rod guide onto rod sec-
tion two and slide the guide into the end of the cylin-
der barrel.

14. Coat the threads of the cylinder rod guide with Loc-
tite #242 then secure the cylinder rod guide to the
cylinder barrel using a suitable spanner wrench.

15. Reconnect the hydraulic hoses to the applicable cyl-

inder ports.

2.15 TILT SWITCH ADJUSTMENT (IF

EQUIPPED)
NOTE: The machine may be equipped with a tilt switch (sen-
sor), factory set to activate when the machine is out
of level in any direction at 5 degrees and will cut out
2 speed drive. Consult factory for tilt sensor adjust- Figure 2-17. Tilt Switch Leveling - Manual Adjustment
ment. The only field adjustment necessary is leveling
the switch on the spring loaded studs. There are two 7. Individually push down on one corner at a time;
methods of adjustment, a manual adjustment and an there should be enough travel to cause the switch to
adjustment using a voltmeter. trip. If the switch does not trip in all three tests, the
flange nuts have been tightened too far. Loosen the
“X” nut and repeat steps 3 through 7.

PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINI-

Voltmeter Adjustment
MUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION
1. Park the machine on a flat, level surface and ensure
AND ADJUSTMENT OF SWITCH.
the machine is level.

Manual Adjustment 2. If the motor is not running, turn the ignition switch to
ON.
1. Park the machine on a flat, level surface and ensure 3. Connect the black lead of the voltmeter to ground
the machine is level. and the red lead to the yellow wire protruding from
the pot on the bottom of the sensor.
NOTE: Ensure switch mounting bracket is level and securely
attached. 4. Adjust the leveling nuts to obtain the highest possi-
ble voltage reading.
2. Level the base of the indicator by tightening the 5. Check the voltage at the trip point in all four direc-
three flange nuts. Tighten each nut through approxi- tions. If the voltage reading is not symmetrical,
mately one half of its spring travel. DO NOT ADJUST repeat step 4 above.
THE “X” NUT DURING THE REMAINDER OF THE
PROCEDURE.

3. With the electrical connections complete, slowly

tighten one of the “Y” nuts until the circuit is closed
(the light on the Platform Control Console illumi-
nates, the tilt alarm sounds).

4. Slowly back off the nut, counting the number of

turns, until the circuit is closed again.

5. Divide the number of turns determined in step 4 in

half. Tighten the nut this many turns. The line deter-
mined by this nut and the “X” nut is now parallel to
the ground.

6. Repeat steps 3 through 5 for the remaining “Y” nut.

The switch is now level.

3120762 – JLG Lift – 2-17

 SECTION 2 - PROCEDURES

Figure 2-18. Tilt Switch Leveling - Voltmeter Adjustment

3. While monitoring the pressure gauge at MP, adjust

2.16 LIMIT SWITCH ADJUSTMENT the lift up relief as follows:

Platform Limit Switch 1532E3 - 1625 psi (112 bar).

The platform limit switch is located on the left side of the 1932E3 - 2000 psi (138 bar).
frame of the machine. When activated, the switch cuts out
the High Drive function. Adjust the switch to activate when 2033E3 - 1525 psi (105 bar).
the platform is raised above the stowed position.
2046E3 - 1800 psi (124 bar).

2646E3 - 1800 psi (124 bar).

2658E3 - 2100 psi (145 bar).

2.17 PRESSURE SETTING PROCEDURES
5. If adjusting the steer pressure, proceed to steer
NOTE: Make all pressure adjustments with motor operating adjustment; if not, remove the pressure gauge from
and hydraulic oil at normal operating temperature. In gauge port MP.
addition, all functions must be operated from the
platform control station in order to achieve full pump
speed. It may be necessary to use an assistant to
Main Relief and High Drive Pressure Switch
adjust the pressure settings while operating the func- Adjustment
tions from the platform control station.
1. Install a pressure gauge at gauge port MP, located at
Lift Relief Adjustments the bottom front of the valve body. The port is identi-
fied by a stamping on the valve body.
1. Install a pressure gauge at gauge port MP, located at 2. Close the steer valve completely by turning clock-
the bottom rear of the valve body. The port is identi- wise.
fied by a stamping on the valve body.
3. Once the steer valve is closed activate the steer
2. From the platform control station, activate the lift up switch in either direction until the steer cylinder bot-
function by pressing the lift switch and activating the toms out.
controller to the full forward position.
4. Adjust your main pressure to 3000 psi (207 bar).

5. Once you have adjusted your main pressure be sure

and reset your steer pressure to 2100 psi (145 bar).

2-18 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

Steer Adjustment check steer right pressure. If necessary, adjust steer

right pressure to 2100 psi (145 bar).
1. If necessary, connect a pressure gauge to gauge
3. Activate drive by pressing the drive switch and acti-
port MP.
vating the controller to the full forward position.
2. Activate drive by pressing the drive switch and acti- While holding the controller, activate steer left and
vating the controller to the full forward position. check steer left pressure. If necessary, adjust steer
While holding the controller, activate steer right and left pressure to 2100 psi (145 bar)..

Figure 2-19. Pressure Setting Adjustments

3120762 – JLG Lift – 2-19

 SECTION 2 - PROCEDURES

Figure 2-20. Drive Motor (Sauer Danfoss)

4. With the housing in the holding device, press the

2.18 DRIVE MOTOR (SAUER DANFOSS) shaft out of the housing. Collect the needle bearings
for possible re-use.
Dismantling
5. Remove the housing from the holding device and
place on a workbench. With a screwdriver, gently
1. Place motor in proper holding device that allows
lever the dust seal ring from the housing.
access to the output shaft.
6. Extract the shaft seal from the housing.
2. Carefully remove end cover sideways being sure to
catch any parts that may fall from the gearwheel. 7. Press the remaining parts out using hydraulic equip-
ment.
3. The needles bearings will fall out during dismantling
and can be collected and reused. The outer ring and 8. Clean all parts carefully with a low aromatic kero-
thrust bearing need not be removed. sene.

2-20 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

Assembly 9. Place the needles in the outer ring and hold them in
place with grease. Carefully place the distributor
NOTE: Before assembly, inspect all parts and replace if nec- plate on the bearing housing so that the shaft enters
essary. the bearing. Press the distributor plate until it stops
on the housing and line up the screw holes.
Before assembly, lubricate all parts with hydraulic oil 10. Place the O-rings (greased) in the gearwheel O-ring
and grease rubber parts with vasoline. recesses. If there is a recess on one end of the
splined hole, position the gearwheel with recess on
1. Turn motor housing so the rear end faces upwards. the same side as the smallest screw hole (stage
Press shaft seal into housing. hole) in the gearwheel rim. Fit the gearwheel set with
2. The bearing race can be fitted in any position. this side facing the motor.

3. Place the needle bearings in the outer ring and hold 11. Clockwise Revolution:
them in place with grease. Place the whole bearing Fit the gearwheel set on the cardan shaft so that the
into the housing. Press the bearing into position top of a tooth in the external teeth of the gearwheel
using pressure equipment if necessary. is vertically over the mark on the cardan shaft. Turn
the gearwheel set counterclockwise until the cardan
4. Carefully insert shaft through bearing housing. shaft and gearwheel engage (15°). Turn the gear-
5. Place O-ring (greased) in bearing housing O-ring wheel rim to line up the screw holes.
recess. 12. Counterclockwise Revolution:
6. Place spring washer on balance plate, insert O-ring Fit the gearwheel set on the cardan shaft so that the
in recess and lubricate with grease. Place balance top of a tooth in the external teeth of the gearwheel
plate lightly in position so that it engages. Be careful is vertically over the mark on the cardan shaft. Turn
not to damage the O-ring. the gearwheel set clockwise until the cardan shaft
and the gearwheel engage (15°). Turn the gearwheel
7. Place the disc valve on the shaft with channels to line up the screw holes.
upwards so that the long tab on the disc valve
engages with the slot in the shaft. 13. Rotate the end cover to line up the screw holes.

8. If there is a difference in the spline length, fit the car- 14. Use new washers and a 13 mm socket spanner.
dan shaft with he long spline end in the output shaft. Torque to 330-380 lbf in (3.75 - 4.25 daNm).
Mark the bottom of the cardan spline that lies adja- 15. Screw in plastic plugs.
cent to the long tab on the disc valve.
16. Turn the motor over and strike the dust seal into
place with a plastic hammer and suitable mandrel.
17. Secure the key in place with tape.

3120762 – JLG Lift – 2-21

 SECTION 2 - PROCEDURES

2.19 POTHOLE PROTECTION SYSTEM LIMIT

SWITCH IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC-
TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-
Adjustment WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI-
CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. REC-
OMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
1. With the pothole protection system in the fully down MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE
position, mount the limit switch on the bracket in the COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS
rear of the machine frame. ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR
BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
2. Adjust the switch to provide for 1/16 inch maximum
clearance between the roller and the cam.
INTRODUCTION
The JLG designed SMART System™ is a 24 Volt multiplex
motor control unit installed on the electric scissor lift mod-
WHEN MOUNTING OR ADJUSTING THE LIMIT SWITCH, BE SURE els 1532E3, 1932E3, 2033E3, 2046E3, 2646E3 and
THAT THE SAFETY PROP IS BEING USED PROPERLY. 2658E3.

3. Tighten the switch mounting hardware. The SMART System™ has reduced the need for exposed
terminal strips, diodes and trimpots and provides simplic-
ity in viewing and adjusting the various personality set-
tings for smooth control of: acceleration, deceleration,
2.20 JLG SMART SYSTEM™ ANALYZER KIT creep and max-speed for the lift, drive, steering and
INSTRUCTIONS optional power deck functions. The function select mem-
brane board, in the upper control box, also eliminates the
need for toggle switches and a separate power enable
button as this feature is built into each function select but-
ton on the board itself.

The lift, drive and optional power deck functions are con-
trolled by a joystick, with steering being controlled by a
rocker switch built into the top of the joystick. Drive, lift,
and the optional power deck functions are selected by
first pushing the appropriate momentary select buttons on
the membrane board and then moving the joystick either
in the “A” or “B” direction. If the joystick is not activated
within three seconds of selecting a function, it will be nec-
essary to re-select a function. High drive and positive trac-
tion are used in conjunction with the drive function.

The motor controller will control current output, as pro-

grammed for smooth operation and maximum cycle time.
Ground control speeds for platform lift and the optional
Figure 2-21. JLG SMART System™ Controller power deck are also programmed into the motor control-
ler. The motor controller also features an adjustable time
limit for positive traction. Another power saving feature is
the high speed drive current limit. This feature will auto-
WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER ON matically control the drive speed and controller output
THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON- when it exceeds the pre-set current limit for a specified
TROLLER FOR THE PROPER MACHINE CONFIGURATION, time and reduce the motor speed, thus conserving power.
INCLUDING OPTIONS. REFER TO ANALYZER KIT NO. 2901443. For safety, the machines are equipped with pothole pro-
tection and elevation cutback. The pothole protection is
employed as the platform is raised. If the pothole protec-
tion does not extend, the drive function will be disabled.
WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER ON When the platform is raised, the drive function goes into
THE MACHINE, ELECTRICAL SILICONE GREASE, JLG PART creep mode.
NUMBER 0100076 OR 7016397, MUST BE APPLIED TO THE BACK
OF THE CONTROLLER.

2-22 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

The JLG SMART System™ controller has a built in LED to PERSONALITIES

indicate any faults. The system stores recent faults which
may be accessed for troubleshooting. Optional equip- MACHINE SETUP
ment includes an hourmeter, beacon light, tilt switch (light
and/or alarm), power deck, power deck extension limit, CALIBRATIONS (level 0 Manufactures Access Only)
function cutout, and ground alarm. These options may be
added later but some must be programmed into the motor If you press ENTER, at the HELP:PRESS ENTER display,
controller when installed. and a fault is present during power up, the analyzer dis-
play will scroll the fault across the screen. If there was no
The SMART System™ may be accessed by utilizing a cus- fault detected during power up, the display will read:
tom designed, hand held analyzer (JLG kit no. 2901443) HELP: EVERYTHING OK
which will display two lines of information at a time, by
scrolling through the program. If ENTER is pressed again, the display moves to the fol-
lowing display:
NOTE: The date code is determined by the first four dig-
its of the controller serial number which is LOGGED HELP
located on the label attached to the front of the
controller. 1: STARTUP (2/1)
The part number of the controller is located on
the controller decal. At this point, the analyzer will display the current fault, if
any are present. You may scroll through the fault logs to
To Connect the Hand Held Analyzer: view what the last fifteen faults were. Use the right and left
arrow keys to scroll through the fault logs. To return to the
beginning, press ESC two times.
1. Connect the four pin end of the cable supplied with
the analyzer, to the top connection of the motor con-
NOTE: The STARTUP (2/1) is not a fault. It is used to sepa-
troller and connect the remaining end of the cable to
rate faults between powerups.
the analyzer.

NOTE: The cable has a four pin connector at each end of When a top level menu is selected, a new set of menu
the cable; the cable cannot be connected back- items may be offered; for example:
wards.
PLATFORM
2. Power up the SMART System™ by turning the lower
key to the platform position and pulling both emer- GROUND
gency stop buttons on.
SYSTEMS
Using the Analyzer: DATA LOG
With the machine power on and the analyzer connected
properly, the analyzer will display the following: VERSIONS

HELP: DRIVE
PRESS ENTER LIFT
At this point, using the RIGHT and LEFT arrow keys, you
STEER
can move between the top level menu items. To select a
displayed menu item, press ENTER. To cancel a selected
GROUND MODE
menu item, press ESC; then you will be able to scroll
using the right and left arrow keys to select a different MACHINE
menu item.
Pressing ENTER with any of the above displayed menus,
The top level menus are as follows:
will display additional sub-menus within the selected
HELP menu. In some cases, such as DRIVE, the next level is the
parameter or information to be changed. Refer to the flow
DIAGNOSTICS chart for what menus are available within the top level
RUN SYSTEMS TEST (NOTE: Ensure machine is menus. You may only view the personality settings for
fully lowered before running systems test) selected menus while in access level 2. Remember, you
may always cancel a selected menu item by pressing the
ACCESS LEVEL ESC key.

3120762 – JLG Lift – 2-23

 SECTION 2 - PROCEDURES

Changing the Access Level of the Hand Held When a machine digit item is selected, press the UP or
Analyzer: DOWN arrow keys to adjust its value, for example:

When the analyzer is first connected, you will be in access GROUND ALARM:
level 2 which enables you to only view most configuration 2=DRIVE
settings which cannot be changed until you enter a pass-
word to advance to a lower level. This ensures that a set- The effect of the machine digit value is displayed along
ting cannot be accidentally altered. To change the access with its value. The above display would be selected if the
level, the correct password must be entered. To enter the machine was equipped with a ground alarm and you
password, scroll to the ACCESS LEVEL menu. For exam- wanted it to sound when driving. There are certain set-
ple: tings allowed to install optional features or select the
machine model.
MENU:
When selecting the machine model to match the size of
ACCESS LEVEL 2 the machine, the personality settings will all default to the
factory recommended settings. Note: Refer to the appro-
Press ENTER to select the ACCESS LEVEL menu. priate Machine Personality Settings Table, and the
Machine Setup Table in the JLG Service Manual for the
Using the UP or DOWN arrow keys, enter the first digit of
recommended factory settings. Refer to the JLG part
the password, 3.
number of the controller, printed on the front label, to
Then using the RIGHT arrow key, position the cursor to select the correct table in the manual.
the right one space to enter the second digit of the pass- NOTE: Password 33271 will give you access to level 1,
word. which will permit you to change all machine person-
Use the UP or DOWN arrow key to enter the second digit ality settings. There are some settings that JLG
of the password which is 3. strongly recommends that you do not change. These
settings are so noted below:
Repeat this process until you have entered all five digits of
the password which is 33271. ELEVATION CUTBACK

Once the correct password is displayed, press ENTER. POSITRAC TIMEOUT

The access level should display the following, if the pass- HIGH DRIVE CURRENT LIMIT
word was entered correctly: HIGH DRIVE TIME LIMIT
MENU:

ACCESS LEVEL 1 CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE

Repeat the above steps if the correct access level is not PERFORMANCE OF YOUR MACHINE.
displayed or you can not adjust the personality settings.

Adjusting Configuration Using the Hand WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER ON
Held Analyzer on All 1600286 Controllers: THE MACHINE, ELECTRICAL SILICONE GREASE, JLG PART
NUMBER 0100076 OR 7016397, MUST BE APPLIED TO THE BACK
Once you have gained access to level 1, and a personality
OF THE CONTROLLER.
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:

PERSONALITIES:
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC-
DRIVE ACCEL 1.0s TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-
WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI-
There will be a minimum and maximum for the value to CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. REC-
ensure efficient operation. The value will not increase if the OMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
UP arrow is pressed when at the maximum value nor will MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE
the value decrease if the DOWN arrow is pressed and the COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS
value is at the minimum value for any particular personal- ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR
ity. If the value does not change when pressing the up and BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
down arrows, check the access level to ensure you are at
access level 1.

2-24 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

Figure 2-22. Organizational Chart

3120762 – JLG Lift – 2-25

 SECTION 2 - PROCEDURES

2.21 MACHINE PERSONALITY SETTINGS

Table 2-2. Machine Personality Settings

PERSONALITY MIN MAX

DRIVE-ACCEL 0.5 SEC 5.0 SEC

DRIVE-DECEL 0 SEC 5.0 SEC

DRIVE CREEP 1% 25.0%

DRIVE SPEED MAX (LOW) 50% 100%

DRIVE SPEED MAX (HIGH) 50% 100%

*ELEVATION MAX *0% *40%

*POSI-TRAC TIME *0 Sec *60 Sec

*HIGH DRIVE OVERCURRENT *50 Amp *200 Amp

HIGH DRIVE TIME OUT 0 Sec 25 Sec

LIFT ACCEL 0.5 Sec 5.0 Sec

LIFT DECEL 0.0 Sec 1.5 Sec

LIFT CREEP 1% 25%

LIFT UP MAX 50% 100%

MAX DOWN 30% 100%

DECK ACCEL 0.5 Sec 5.0 Sec

DECK DECEL 0 Sec 5 Sec

DECK CREEP 1% 25%

DECK EXT MAX 0 100%

DECK RET MAX 0 100%

STEER STATIC 20% 50%

STEER (DRIVE COMP) 0 35%

GROUND LIFT UP MAX 0% 100%

GROUND LIFT DOWN 0% 100%

GROUND DECK OUT 0% 100%

GROUND DECK IN 0% 100%

*JLG strongly recommends that these settings not be NOTE: Personality settings can be adjusted within the
changed. Changing these settings may adversely adjustment range in order to achieve optimum
affect the performance of your machine. machine performance.

2-26 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

2.22 MACHINE MODEL DEFAULT SETTINGS

Table 2-3. Machine Model Default Settings Chart

Adjustment 1532E3 1932E3 2033E3 2046E3 2646E3 2658E3

DRIVE ACCELERATION 1.0 sec 1.0 sec 1.0 sec 1.0 sec 1.0 sec 1.0 sec

DRIVE DECELERATION 0.5 sec 0.5 sec 0.5 sec 0.5 sec 0.5 sec 0.5 sec

DRIVE CREEP 10% 10% 12% 12% 12% 12%

DRIVE SPEED MAX (LOW) 70% 70% 100% 100% 100% 100%

DRIVE SPEED MAX (HIGH) 70% 70% 85% 85% 85% 85%

ELEVATION MAX* 25%* 25%* 30%* 30%* 37%* 36%*

POSITRAC TIME 10 sec 10 sec 10 sec 10 sec 10 sec 10 sec

HIGH DRIVE OVER CURRENT 140 amps 140 amps 140 amps 140 amps 140 amps 140 amps

HIGH DRIVE TIME OUT* 5.0 sec* 5.0 sec* 5.0 sec* 5.0 sec* 5.0 sec* 5.0 sec**

LIFT ACCEL 1.0 sec 1.0 sec 1.0 sec 1.0 sec 1.0 sec 1.0 sec

LIFT DECEL 0.0 sec 0.0 sec 0.0 sec 0.0 sec 0.0 sec 0.0 sec

LIFT CREEP 10% 10% 15% 15% 15% 15%

LIFT UP MAX 90% 90% 100% 100% 100% 100%

DECK ACCEL 0.5 sec 0.5 sec 0.5 sec 0.5 sec 0.5 sec 0.5 sec

DECK DECEL 0.0 sec 0.0 sec 0.0 sec 0.0 sec 0.0 sec 0.0 sec

DECK CREEP 10% 10% 10% 10% 10% 10%

DECK EXTENSION SPEED MAX. 100% 100% 100% 100% 100% 100%

DECK RETRACTION MAX 80% 80% 80% 80% 80% 80%

STATIC STEER 30% 30% 30% 30% 30% 30%

STEER (DRIVE COMP) 15% 15% 15% 15% 15% 15%

GROUND LIFT UPMAX 100% 100% 100% 100% 100% 100%

GROUND DECK IN MAX 50% 50% 50% 50% 50% 50%

GROUND DECK OUT MAX 50% 50% 50% 50% 40% 40%

NOTE: * JLG strongly recommends that these settings not

be changed. Changing these settings may adversely
CHANGING THE MACHINE MODEL WILL SET ALL PERSONALI- affect the performance of your machine.
TIES BACK TO THE FACTORY DEFAULT SETTINGS. CHECK THE
MACHINE MODEL ADJUSTMENT CHART FOR THE CORRECT
SETTINGS FOR EACH MODEL. IF YOUR MACHINE DOES NOT
MATCH THE PROPER SETTINGS FOR EACH MODEL, ADJUST
THE SETTINGS AS NECESSARY IN ACCORDANCE WITH THE
CHART.

3120762 – JLG Lift – 2-27

 SECTION 2 - PROCEDURES

2.23 MACHINE CONFIGURATION

INFORMATION
NOTE: The following information is to be used when working
with the MACHINE SETUP menu. When configuring
the E Series scissor lift, the machine configuration
must be completed before any personality settings
can be changed. Changing the personality settings
first and then changing the model number of the
machine configuration will cause the personality set-
tings to return to default values .

Table 2-4. Machine Configuration Programming Information

Default Setting
Configuration Digit Number Description Before
Programming

1 1 MODEL 1532E3 3
(MODEL NUMBER) 2 MODEL 1932E3
3 MODEL 2033E3
4 MODEL 2046E3
5 MODEL 2646E3
6 MODEL 2658E3

2 0 No tilt switch installed. 0

(TILT SWITCH)
1 Tilt switch installed for North american, CE, and optional for Latin American
machines. This digit will allow the SMART System™ to indicate when the machine is
out of level by lighting the light in the platform box. If the machine is elevated and tilted,
the SMART System™ will also sound the platform alarm continuously. No functions
are cutback or cutout.

2 Tilt switch for Australia, Japanese, and option for Latin American machines. This digit
will allow the SMART System™ to indicate when the machine is out of level by lighting
the light in the platform box. If the machine is elevated and tilted, the SMARtT Sys-
tem™ will also sound the platform alarm continuously and the lift up and drive func-
tions are cutout.l

3 0 No power deck installed. 0

(POWER DECK)
1 Machine equipped with power deck.

4 0 Deck extension limit switch not installed. (This cannot be zero if there is a power deck 0
(DECK EXT. LIMIT installed.)
SWITCH)
1 Cuts out LIFT DOWN when deck is extended. This digit is used with roll out decks that
require a deck extension cutout. Sounds platform alarm for one second on, one sec-
ond off, one second on, and three seconds off while operator tries to perform the func-
tion that has been cut out (provided the platform alarm has been installed).

2 Cuts out HIGH DRIVE when deck is extended and below elevation. Cuts out DRIVE
when deck is extended and above elevation. This digit is used with a power deck.
Sounds platform alarm for one second on, one second off, one second on, and three
seconds off while operator tries to perform the function that has been cut out and dur-
ing the LIFT DOWN function (provided the platform alarm has been installed).

2-28 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

Table 2-4. Machine Configuration Programming Information

Default Setting
Configuration Digit Number Description Before
Programming

5 0 No function cutout installed. 0

(FUNCTION CUTOUT)
1 Overload switch for French, Japanese machines. — Cuts out all functions. Sounds
platform alarm for two seconds on, two seconds off, while operator tries to perform the
function that has been cut out (provided the platform alarm is installed).

6 0 No ground alarm installed. 0

(GROUND ALARM)
1 Descent alarm. — Sounds when LIFT DOWN is active.

2 Travel alarm. — Sounds when DRIVE function is active.

3 Motion alarm. — Sounds whenever the DRIVE, LIFT or DECK function is active.

7 0 No drive cutout switch installed. 0

(DRIVE CUTOUT)
1 Cuts out DRIVE when deck is elevated above a predetermined elevation (varies with
machine model).

8 0 No arm guard cutout. 0

(ARM GUARDS))
1 European (CE Specification) machines — LIFT DOWN cutout must activate when the
gap between the arms is 5 in. to 8 in. (13 cm to 20 cm). Here it will cut out LIFT DOWN
and sound the platform alarm for 1/2 second on, 1/2 second off, and repeat this for
three seconds. After three seconds, the operator must re-select the LIFT function and
continue to operate LIFT DOWN. If the wires to the limit switch used to detect the deck
height are cut or the switch has failed, the platform alarm will sound as mentioned. The
operator can re-select the LIFT function and then LIFT DOWN for ten seconds, at
which time it will cut out again and the process must be repeated.

9 0 LED Only 0
(Flash Codes)
1 LED and lamps in platform control box

2 LED and alarm

3 LED, lamps in control box and alarm

3120762 – JLG Lift – 2-29

 SECTION 2 - PROCEDURES

2.24 JLG SMART SYSTEM™ HELP

MESSAGES AND FLASH CODES
Table 2-5. Help Messages

NO FLASH CODE IS INDICATED FOR THE FOLLOWING HELP MESSAGES; THEY ARE INTENDED TO HINT AT A POSSIBLE PROBLEM IF THE
MACHINE IS NOT BEHAVING AS EXPECTED

EVERYTHING OK The "normal" help message in platform mode.

GROUND MODE OK The “normal” help message in ground mode.

ALARM SOUNDING: ARMGAURD PROTECTION ACTIVE Arm guard protection has tripped during lift down and is preventing lift down for three
seconds.

ALARM SOUNDING: DECK EXTENDED DURING LIFT DOWN The deck extension cutout is preventing lift down.

ALARM SOUNDING: OVERLOADED The function cutout is active; some functions may be prevented.

ALARM SOUNDING: TILTED & ABOVE ELEVATION The machine is tilted while above elevation; some functions may be prevented.

DECK PREVENTED - NOT AVAILABLE A deck function has been selected but there is no power deck.

DIFFERENT FUNCTION SELECTED & IGNORED A platform function selection (drive, lift, or deck) has been pressed while another func-
tion is in use.

DRIVING AT CUTBACK - ABOVE ELEVATION Drive speed is limited to cutback because the machine is above elevation.

DRIVING AT CUTBACK - POTHOLE STILL ENGAGED drive speed is limited to cutback because the pothole protection is still engaged while
the machine is not above elevation.

FUNCTION SELECTED BUT TRIGGER SWITCH OPEN A function has been selected but the trigger switch is open; when the trigger switch is
closed the function will begin if it is still selected.

HIGH DRIVE PROBLEM - CUTOUT The high drive function has been selected but is prevented by a cutout (high drive is not
allowed while above elevation or when the deck is extended.

HIGH DRIVE PROBLEM - MOTOR CURRENT EXCEEDED The high drive function was selected but was ended because pump motor current was
to high

JOYSTICK MOVED BUT NO FUNCTION SELECTED The drive, lift or deck function must be selected before the joystick is moved from neu-
tral.

POSITRAC PROBLEM - NOT ALLOWED DURING HIGH DRIVE The positrac function has ben selected but is not allowed while the high drive function is
in use.

PUMP MOTOR AT CURRENT LIMIT Pump motor current has reached the maximum allowed and is being limited.

STEER SELECTED BUT TRIGGER SWITCH OPEN Steering has been selected but the trigger switch is open; when the trigger switch is
closed steering will begin if it is still selected.

TESTS ACTIVE - RECYCLE EMS TO END The system tests have been activated; normal machine operation is not allowed.

2-30 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

Table 2-6. JLG SMART System™ Help Messages & Flash Codes

Code Description

2-1 - Indicates problems with EMS inputs STARTUP - Neither EMS is active - the system is just switching on or is discharging the
capacitor bank.
A welded line contactor might also cause this.

2-2 - Indicates problems with platform controls ALL FUNCTIONS PREVENTED - NO DATA FROM PLATFORM BOX - The signal from
the MUX board in the platform box is not available; drive, lift and deck functions cannot be
selected.
FUNCTION PROBLEM - PERMANENTLY SELECTED - The drive, lift or deck function
select is active for more than ten seconds; any active function will be stopped.
FUNCTIONS LOCKED OUT - RELEASE THEN RESELECT - The selected function is
not allowed; release the joystick to clear the fault.
HIGH DRIVE PROBLEM - PERMANENTLY SELECTED - The high drive function select
is active for more than ten seconds; the high drive function will be stopped.
FUNCTION SELECTED BUT TRIGGER NEVER CLOSED - Occurs after ten seconds
with the joystick in neutral, but trigger switch never closed.
JOYSTICK FAULTY - WIPER OUT OF RANGE - Occurs if wiper voltage is invalid.
JOYSTICK FAULTY - CENTER OUT OF RANGE - Occurs if center tap voltage is invalid.
JOYSTICK FAULTY - STEER SWITCHES ACTIVE TOGETHER
JOYSTICK LOCKED OUT - RELEASE THEN RESELECT
PORITRAC PROBLEM - PERMANENTLY SELECTED
TRIGGER INTERLOCK TRIPPED - Trigger switch was closed for more than ten sec-
onds with no function selected.
WAITING FOR TRIGGER SWITCH TO BE OPEN - Trigger switch was closed when plat-
form mode was selected.

2-3 - Indicates problems with ground controls GROUND FUNCTIONS LOCKED OUT - RELEASE THEN RESELECT - A ground
mode function (lift or deck) was selected when ground mode was selected

2-5 - Indicates a function is prevented due to a cutout DECK PREVENTED - FUNCTION CUTOUT ACTIVE
DRIVE PREVENTED - DECK EXTENDED & ABOVE ELEVATION
DRIVE PREVENTED - DRIVE CUTOUT ACTIVE - Drive is selected while drive cutout is
active and drive cutout is configured to prevent drive.
DRIVE PREVENTED - FUNCTION CUTOUT ACTIVE - Drive is selected while function
cutout ("overload") is active and configured to cut out drive functions.
DRIVE PREVENTED - POTHOLE NOT ENGAGED
DRIVE PREVENTED - TILTED & ABOVE ELEVATION - Drive is selected while tilted
and above elevation and tilt is configured to prevent drive.
LIFT DOWN CUTOUT - ARMGAURD PROTECTION ACTIVE
LIFT DOWN PREVENTED - DECK EXTENDED
LIFT PREVENTED - FUNCTION CUTOUT ACTIVE
LIFT UP PREVENTED - TILTED & ABOVE ELEVATION
STEER LOCKED OUT - RELEASE THEN RESELECT
STEER PREVENTED - DECK EXTENDED & ABOVE ELEVATION
STEER PREVENTED - FUNCTION CUTOUT ACTIVE
STEER PREVENTED - NOT AVAILABLE
STEER PREVENTED - TILTED & ABOVE ELEVATION

3-1 - Indicates that a contactor did not close when ener- OPEN-CIRCUIT LINE CONTACTOR - The capacitor bank charge did not increase to
gized battery supply when line contactor was energized (this could be due to a power wiring
error.

3-2 - Indicates that a contactor did not open when de-ener- WELDED LINE CONTACTOR - The capacitor bank charge did not decrease from bat-
gized tery supply when line contactor was de-energized (this could be due to a power wiring
error).

3120762 – JLG Lift – 2-31

 SECTION 2 - PROCEDURES

Table 2-6. JLG SMART System™ Help Messages & Flash Codes

Code Description

3-3 - Indicates that a contactor coil is short-circuit SHORT-CIRCUIT LINE CONTACTOR COIL - The line contactor was not energized
when required, due to coil over current protection.
VALVE OR LINE CONTACTOR ENERGIZED - CHECK WIRING - The drive circuit to the
line contactor or a valve is active when no driver circuit is turned on (this could be due to a
wiring error to the valves or line contactor).

4-2 - indicates that the controller is over temperature CONTROLLER TO HOT - PLEASE WAIT - The controller heat sink temperature
reached 75 degrees. The controller is shut down until it cools to below 70 degrees.

4-4 - Indicates problems with the battery supply BATTERY TOO LOW - SYSTEM SHUT DOWN - Battery voltage is below 17V. EMS
recycle required.
BATTERY TOO HIGH - SYSTEM SHUT DOWN - Battery voltage is above 30 V. EMS
recycle required.

7-7 - Indicates problems with a motor CAPACITOR BANK FAULT - CHECK MOTOR WIRING - The capacitor bank is not
charging. This is probably due to a power wiring error causing illegal current drain; it
could also be due to a very low battery supply.
POINT A LOW - CHECK POWER CIRCUITS - Pump point A is low when the MOSFETs
are off. This is probably due to power wiring error.
PUMP MOTOR OPEN-CIRCUIT - CHECK MOTOR & WIRING - Pump point A is col-
lapsing when the pump MOSFETs are pulsed. This is probably due to an open circuit
pump motor or a power wiring error.
PUMP MOTOR STALLED - CHECK MOTOR & WIRING - The pump MOSFET protec-
tion circuit is active. This is due to massive current drain and could be a stalled pump
motor or power wiring error.

9-9 - Indicates problems with the controller CONTROLLER FAILURE: HWFS TEST STALLED - The hardware fail safe tests did not
complete, but no reason can be determined.
CONTROLLER FAILURE: HWFS TEST STALLED 15 - The hardware fail safe tests
failed because the contactor drive fail safe did not trip within the allowed test time.
NOTE: Anytime a reading of a 15- code appears the controller must
be replaced.

2-32 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

between items in the same level. The UP/DOWN arrow

2.25 ANALYZER MENU STRUCTURE keys alter a value if allowed
In the following structure descriptions, an intended item is
selected by pressing ENTER; pressing ESC steps back to
the next outer level. The LEFT/RIGHT arrow keys move

Table 2-7. Analyzer Menu Structure

ITEM TO BE VIEWED
TOP LEVEL MENU SUB LEVEL MENU DESCRIPTION DISPLAY
OR CHANGED

HELP;PRESS ENTER
HELP Displays current help/fault message
LOGGED HELP Log of most recent help/fault messages: LEFT/RIGHT view

DIAGNOSTICS ASPC IN... Displays current controller mode.

NEUTRAL/DRIVE/FORWARD/LIFT/etc.
PLATFORM
JOYSTICK Displays joystick demand 0%...100% Preceded by “+” for
forward/up/out, or by “-” for reverse/down/in.

STEER Displays steer status. (NONE/LEFT/RIGHT/etc.)

POSI-TRAC Displays posi-trac switch status (OPEN/CLOSED)

HIGH DRIVE Displays high drive switch status (OPEN/CLOSED)

TRIGGER Displays trigger switch status (OPEN/CLOSED)

DRIVE Displays drive mode select switch status (OPEN/CLOSED)

LIFT Displays lift mode select switch status (OPEN/CLOSED)

DECK Displays deck mode select switch status (OPEN/CLOSED)

Not displayed if POWER DECK = NO

GROUND
UP Displays ground lift up switch status (OPEN/CLOSED)

DOWN Displays ground lift down switch status (OPEN/CLOSED)

OUT Displays ground deck out switch status (OPEN/CLOSED)

Not displayed if POWER DECK = NO

IN Displays ground deck in switch status (OPEN/CLOSED)

Not displayed if POWER DECK = NO

3120762 – JLG Lift – 2-33

 SECTION 2 - PROCEDURES

Table 2-7. Analyzer Menu Structure

ITEM TO BE VIEWED
TOP LEVEL MENU SUB LEVEL MENU DESCRIPTION DISPLAY
OR CHANGED

SYSTEMS
BATTERY Displays measured battery voltage
NOTE: Only accurate when line contactor closed

TEMPERATURE Displays measured heatsink temperature

PUMP VOLT Displays calculated pump motor voltage

PUMP AMP Displays calculated pump motor current

ELEVATION Displays elevation cutout switch status (OPEN/CLOSED)

Closed with platform fully lowered

DIAGNOSTICS/SYSTEMS FUNCTION C/O Displays function cutout switch status (OPEN/CLOSED)

(Continued) Not displayed if FUNTION CUTOUT=NO

DECKC/O Displays function cutout switch status (OPEN/CLOSED)

Not displayed if POWER DECK=NO

DRIVE C/O Displays function cutout switch status (OPEN/CLOSED)

Not Displayed if DRIVE CUTOUT = NO

POTH C/O Displays pothole cutout switch status (OPEN/CLOSED)

TILT Displays tilt switch status (LEVEL /TILTED)

Not Displayed if TILT SWITCH = NO

ARMGUARD Displays armguard cutout switch status (OPEN/CLOSED)

Not displayed if ARMGUARD CUTOUT = NO

2-34 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

Table 2-7. Analyzer Menu Structure

ITEM TO BE VIEWED
TOP LEVEL MENU SUB LEVEL MENU DESCRIPTION DISPLAY
OR CHANGED

DATALOG
ON Displays total controller on time
NOTE: Up to four minutes lost at switch-off

DRIVE Displays total controller drive operation time

LIFT Displays total controller lift operation time

DECK Displays total controller deck operation time

NOTE: Not displayed if POWER DECK = NO

PUMP Displays total controller pump running time

NOTE: Includes drive, lift up, deck and steer

RENTAL Displays total controller pump running time

NOTE: Can be reset

ERASE RENTAL Not available in level 3

(YES:ENTER,NO ESC) ENTER resets rental datalog time to zero

MAX. TEMP
Displays maximum measured heatsink temperature
MIN. TEMP
Displays minimum measured heatsink temperature
MAX BATTERY
Displays maximum measured battery voltage

VERSIONS
ASPC Displays controller software version

ANALYZER Displays analyzer software version

ACTIVATE TESTS Not available once tests are activated

YES:ENTER,NO:ESC ENTER activates system test

NOTE: Cannot be done while controller is use (trigger switch
closed)

RUN SYSTEM TEST ENTER starts system test

(Machine must be fully
lowered before run- Not available until tests are activated
ning systems test)
Displays messages while system test runs

Some messages are prompts, requiring user intervention

ENTER can be pressed if a fault has been noted and to con-

tinue the system test.
NOTE: A flashing message is critical, and prevents the sys-
tem test from running.

3120762 – JLG Lift – 2-35

 SECTION 2 - PROCEDURES

Table 2-7. Analyzer Menu Structure

ITEM TO BE VIEWED
TOP LEVEL MENU SUB LEVEL MENU DESCRIPTION DISPLAY
OR CHANGED

ACCESS LEVEL Displays the current access level

Level 3 - Personalities cannot be changed
Level 2 - Most personalities can be changed
Level 1 - All personalities can be changed

CODE Allows access level password to be entered

Use LEFT/RIGHT to select digit
Use UP/DOWN to change digit
Use ENTER to update access level

PERSONALITIES
DRIVE
ACCEL Displays/adjusts drive acceleration

DECEL Displays/adjusts drive deceleration

CREEP Displays/adjusts minimum drive speed

LOW MAX Displays/adjusts maximum "low" drive speed

NOTE: Used when high drive not selected

HIGH MAX Displays/adjusts maximum "high" drive speed

NOTE: Used when high drive not selected

ELEVATED MAX Displays/adjusts maximum drive speed elevated

NOTE: Used when elevation or pothole cutout switches are
limiting max speed
NOTE: Only adjustable in access level 1

POSI-TRAC Displays/adjusts posi-trac engaged time-out

HIGH DRIVE AMP Displays /adjusts high drive motor overload current
NOTE: Only adjustable in access level 1

HIGH DRIVE Displays/adjusts high drive motor overload time-out

LIFT
ACCEL Displays/adjusts lift acceleration

DECEL Displays/adjusts lift deceleration

CREEP Displays/adjusts minimum lift (up) speed

MAX UP Displays/adjusts maximum lift (up) speed

MAX DOWN N/A Displays if there is no lift down (gravity)

Displays/adjusts for power down machines for maximum lift
down speed

2-36 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

Table 2-7. Analyzer Menu Structure

ITEM TO BE VIEWED
TOP LEVEL MENU SUB LEVEL MENU DESCRIPTION DISPLAY
OR CHANGED

DECK
ACCEL Displays/adjusts deck acceleration

DECEL Displays/adjusts deck deceleration

CREEP Displays/adjusts minimum deck speed

MAX OUT Displays/adjusts maximum deck out speed

MAX IN Displays/adjusts maximum deck in speed

STEER
STATIC Displays/adjust steer speed
NOTE: Used when not driving

DRIVE COMP Displays/adjusts steer compensation speed

NOTE: Used as an additive when driving
NOTE: Only adjustable in access level 1

GROUND MODE
LIFT UP Displays/adjusts fixed lift up speed

LIFT DOWN N/A Displays if no power lift down

NOTE: Adjustable for power down machines

DECK OUT Displays/adjusts fixed deck speed out

NOTE: Not displayed if POWER DECK = NO

DECK IN Displays/adjusts fixed deck speed in

NOTE: Not displayed if POWER DECK = NO
MACHINE
CURRENT Displays/adjusts maximum motor current
NOTE: DO NOT ADJUST

3120762 – JLG Lift – 2-37

 SECTION 2 - PROCEDURES

Table 2-7. Analyzer Menu Structure

ITEM TO BE VIEWED
TOP LEVEL MENU SUB LEVEL MENU DESCRIPTION DISPLAY
OR CHANGED

MACHINE SETUP
MODEL NUMBER Displays/adjusts machine model
NOTE: All personalities reset to default when model number
is altered

TILT SWITCH Displays/adjusts tilt switch presence/function

POWER DECK Displays/adjusts power deck presence

DECK EXT. LIMIT Displays/adjusts deck extension cutout switch presence/

function

FUNCTION CUTOUT Displays/adjusts function cutout switch presence/function

GROUND ALARM Displays/adjusts ground alarm presence/function

DRIVE CUTOUT Displays/adjusts drive cutout switch presence/function

ARMGAURD CUTOUT Displays/adjusts armgaurd cutout switch presence/function

FLASH CODE Displays/adjusts how fault flash codes are indicated

CALIBRATIONS NOTE: Only available at level 1

CURRENT Displays motor current calibration

TEMPERATURE Displays heatsink temperature calibration

2-38 – JLG Lift – 3120762

 SECTION 2 - PROCEDURES

2.26 PREVENTIVE MAINTENANCE AND

INSPECTION SCHEDULE JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL
The preventive maintenance and inspection checks are INSPECTION BE PERFORMED IN ACCORDANCE WITH THE
listed and defined in the following table. This table is “ANNUAL MACHINE INSPECTION REPORT” FORM.
divided into two basic parts, the “AREA” to be inspected
NOTE: This machine requires periodic safety and mainte-
and the “INTERVAL” at which the inspection is to take
nance inspections be a JLG Dealer. A decal located
place. Under the “AREA” portion of the table, the various
on the frame affords a place to record (stamp)
systems along with the components that make up that
inspection dates. Notify dealer if inspection is over-
system are listed. The “INTERVAL” portion of the table is
due.
divided into five columns representing the various inspec-
tion time periods. The numbers listed within the interval
column represent the applicable inspection code for The inspection and maintenance code numbers are as fol-
which that component is to be checked. lows:

The checks and services listed in this schedule are not 1. Check for proper and secure installation.
intended to replace any local or regional regulations that 2. Check for visible damage and legibility.
may pertain to this type of equipment nor should the lists
be considered as all inclusive. Variances in interval times 3. Check for proper fluid level.
may occur due to climate and/or conditions and depend- 4. Check for any structural damage; cracked or broken
ing on the location and use of the machine. welds; bent or warped surfaces.
JLG Industries requires that a complete annual inspection
5. Check for leakage.
be performed in accordance with the “Annual Machine
Inspection Report” form. Forms are supplied with each 6. Check for presence of excessive dirt or foreign
new machine and are also available from JLG Customer material.
Service. Form must be completed and returned to JLG
Industries. 7. Check for proper operation and freedom of move-
ment.
8. Check for excessive wear or damage.
9. Check for proper tightness and adjustment.
10. Drain, clean and refill.
11. Check for proper operation while pump/motor is
running.
12. Check for proper lubrication.
13. Check for evidence of scratches, nicks or rust and
for straightness of rod.
14. Check for condition of element; replace as neces-
sary.
15. Check for proper inflation.
16. Check Inspection Decal for current inspection
stamp.
*Inspection and Maintenance Code 10 to be performed
every two years (1200 hours).

3120762 – JLG Lift – 2-39

 SECTION 2 - PROCEDURES

Table 2-8. Preventive Maintenance and Inspection Schedule

AREA INTERVAL
DAILY WEEKLY MONTHLY 3 MONTH 6 MONTH 1 YEAR
PLATFORM
1. Controller 1,11
2. Switches 1,11
3. Placards and Decals 1,2
4. Control Tags 1,2
5. Hose and Cable 4,8
6. Wear Pads 8
7. Handrail and Chains 1,4
CHASSIS
1. Batteries 3 5
2. Battery Charger 1
3. Hydraulic Pump/Motor 1 5
4. Valves 1 5
5. Hydraulic Filter (See Lubrication Chart) 5
6. Hydraulic hoses and Tubing 1 5
7. Hydraulic Oil Tank* 1 5
8. Hydraulic Tank Breather 6 14
9. Lift Cylinder 1,12 5,6,13 4
10. Limit Switch 1,7
11.Placards and Decals 1,2 16
12. Wheel and Tire Assemblies 1 8 9
13. Drive Motors 1,5,6
14. Drive Brake 1,6 8
15. Steer Cylinder 1 5,6,13 4
16. Steer Components 1 4,6 8 12
17. Wheel Bearings 8
18. Sizzor Arms 1,4
19. Safety Prop 1,4
20. Wear Pads 8
21. Pivot Pins/Bolts 1,4 7,8
22. Switches, Ground Control 1,11
23. Control Tags 1,2
24. Hose and Cable 1 4,8

2-40 – JLG Lift – 3120762

 SECTION 3 - TROUBLESHOOTING

SECTION 3. TROUBLESHOOTING

3.1 GENERAL 3.3 HYDRAULIC CIRCUIT CHECKS

This section contains troubleshooting information to be The first reference for improper function of a hydraulic sys-
used for locating and correcting most of the operating tem, where the cause is not immediately apparent, should
problems which may develop in the aerial platform. If a be the Troubleshooting Chart. The best place to begin the
problem should develop which is not presented in this problem analysis is at the power source (pump). Once it is
section or which is not corrected by listed corrective determined that the pump is serviceable, then a system-
actions, technically qualified guidance should be obtained atic check of the circuit components, beginning with the
before proceeding with any maintenance. control, would follow. For aid in troubleshooting, refer to
the Illustrated Parts Manual for hydraulic diagrams of the
various circuits.
3.2 TROUBLESHOOTING INFORMATION
The troubleshooting procedures applicable to the aerial
platform are listed and defined in Table 3-1, Hydraulic 3.4 JLG SMART SYSTEM™
System Troubleshooting. The JLG SMART System™ uses a 24 Volt multiplex motor
Each malfunction within an individual group or system is control unit, working in conjunction with a joystick control-
followed by a listing of probable causes which will enable ler and several switches, to operate all machine functions.
determination of the applicable remedial action. The prob- The SMART System™ has a built-in LED to indicate any
able causes and the remedial action should, where possi- faults which occur during operation of the machine. The
ble, be checked in the order listed in the tables. system also stores the last ten trouble faults for use in
It should be noted that there is no substitute for a thor- troubleshooting the machine. Each fault is indicated by a
ough knowledge of the equipment and related systems. first sequence of flashes, then short pause, followed by a
second sequence, then a long pause before everything
It should be recognized that the majority of the problems repeats.
arising in the machine will be centered in the hydraulic
and electrical systems. For this reason, every effort has When a fault occurs in normal operation, the flash fault
been made to ensure that all likely problems in these repeats while the fault is present; as far as possible nor-
areas are given the fullest possible treatment. In the mal operation continues. If there is more than one fault
remaining machine groups, only those problems which present, the ‘most important two’ will be indicated alter-
are symptomatic of greater problems which have more nately. Faults are grouped according to the first digit; the
than one probable cause and remedy are included. This second digit provides an extra diagnostic indication.
means that problems for which the probable cause and In addition, the control unit may be programmed for any
remedy may be immediately obvious are not listed in this future options that are added to the machine. The SMART
section. System™ may be adjusted using a custom designed ana-
The first rule for troubleshooting any circuit that is hydrau- lyzer or special system software installed on a personal
lically operated and electrically controlled is to determine computer (PC) or a laptop computer, operating under
if the circuit is lacking hydraulic oil and electrical control DOS or Windows. Both the analyzer (JLG kit no. 2901443)
power. This can be ascertained by overriding the bypass and the computer software (JLG kit no. 2900874) are
valve (mechanically or electrically) so that oil is available available from JLG and include a connecting cable and
to the function valve, then overriding the function valve SMART System™ adjustment procedures.
mechanically. If the function performs satisfactorily, the
problem exists with the control circuit.
WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER ON
THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON-
TROLLER FOR THE PROPER MACHINE CONFIGURATION,
INCLUDING OPTIONS. REFER TO ANALYZER KIT NO. 2901443.

3120762 – JLG Lift – 3-1

 SECTION 3 - TROUBLESHOOTING

Table 3-1. Hydraulic System Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Hydraulic pump noisy Air bubbles in oil (Reservoir too low) Replenish oil as necessary

Oil filter dirty Clean and/or replace filter as necessary

Pump cavitating (Vacuum in pump due to Oil in reservoir low Replenish oil as necessary
oil starvation)
Restricated reservoir air vent Clean vent

Oil viscosity too high Drain system and replace with recommended
oil.Rrefer to Hydraulic Oil Table

System overheating Oil viscosity too high Drain system and replace with recommended
oil.Rrefer to Hydraulic Oil Table

Main relief set too high Adjust relief valve to proper pressure

Hydraulic system too low Replenish oil as necessary

Pump not delivering oil Defective pump on motor Repair or replace motor

System pressure too low Main relief valve set too low Reset as required

Hydraulic pump not functioning properly Repair or replace pump

Leak in component, line or fitting Repair or replace component, line or fitting

Scored valve spool; scored cylinder Replace valve; replace cylinder

System(s) operate erratically Sticking or binding valve cartridge, piston rod, Clean, repair or replace components as neces-
etc. sary

Hydraulic oil not at operating temperature Allow oil sufficient time to warm up

3-2 – JLG Lift – 3120762

 SECTION 3 - TROUBLESHOOTING

LIFT RELIEF SET @

( SEE MANUAL PER MODEL)

STEER RELIEF
SET @ 2100 PSI

Figure 3-1. Hydraulic Schematic - (2033E3/2046E3/2646E3/2658E3)

3120762 – JLG Lift – 3-3

 SECTION 3 - TROUBLESHOOTING

U3
JLG SMART SYSTEM
MICROPROCESSOR

Figure 3-2. Electrical Schematic - Sheet 1 of 2

3-4 – JLG Lift – 3120762

 SECTION 3 - TROUBLESHOOTING

U3
JLG SMART SYSTEM
MICROPROCESSOR

1282880 L
Figure 3-3. Electrical Schematic - Sheet 2 of 2

3120762 – JLG Lift – 3-5

 SECTION 3 - TROUBLESHOOTING

BEACON

MOTOR
327

PLATFORM
CONSOLE
BOX

TO
LINE
CONTACTOR
RELAY LINE
CONTACTOR
RELAY

WORK LIGHT

VALVE
TO
BATTERIES

+
ALARM

HORN

TEMPERATURE
SWITCH

Figure 3-4. Electrical Componants Installation - Sheet 1

3-6 – JLG Lift – 3120762

 SECTION 3 - TROUBLESHOOTING

BATTERY
CHARGER

HAND HELD
ANALYZER

TILT
ALARM PLATFORM
DESCENT
DELAY
(EURO)
TO
LINE
CONTACTOR
RELA Y

FROM
J2 VALVE
HARNESS

GROUND
CONTROLS

POT-HOLE
PROTECTION CHARGER
SYSTEM MACHINE
LOCKOUT
(AUSTRALIAN ONLY)

DRIVE
CUT-OUT

LIFT DOWN
SOLENOID

DECK
EXTENSION
CUT-OUT

ELEVATION OVERLOAD
SWITCH PRESSURE
(HI-DRIVE SWITCH
LIMIT) (JAPANESE/
FRENCH SPEC)

Figure 3-5. Electrical Componants Installation - Sheet 2

3120762 – JLG Lift – 3-7

 SECTION 3 - TROUBLESHOOTING

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3-8 – JLG Lift – 3120762

 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Fax: (717) 485-6417

JLG Worldwide Locations

JLG Industries (Australia) JLG Industries (UK) JLG Deutschland GmbH JLG Industries (Italia)
P.O. Box 5119 Unit 12, Southside Max Planck Strasse 21 Via Po. 22
11 Bolwarra Road Bredbury Park Industrial Estate D-27721 Ritterhude/lhlpohl 20010 Pregnana Milanese - MI
Port Macquarie Bredbury Bei Bremen Italy
N.S.W. 2444 Stockport Germany Phone: (39) 02 9359 5210
Australia SK6 2sP Phone: (49) 421 693 500 Fax: (39) 02 9359 5845
Phone: (61) 2 65 811111 England Fax: (49) 421 693 5035
Fax: (61) 2 65 810122 Phone: (44) 870 200 7700
Fax: (44) 870 200 7711

JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska
Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Fax: (55) 19 3295 1025

JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal Sweden
Phone: (44) 1 698 811005 South Africa Spain Phone: (46) 8 506 59500
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (27) 11 453 1342 Fax: (34) 93 77 11762