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SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE

5-30

– JLG Lift –

3121272

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POWER MODULE FAILURE - INTERNAL
ERROR

A problem has been detected with the power
module.

Cycle machine power on /off a few times if this doesn’t clear the DTC,
refer problem to a qualified JLG mechanic.

9-9 Hardware

DTC

FAULT MESSAGE

DESCRIPTION

CHECK

Содержание 1932RS/6RS

Страница 1: ...Operation and Safety Manual ANSI Original Instructions Keep this manual with the machine at all times Model s 1932RS 6RS 3248RS 10RS 3121272 June 29 2018 Rev F...

Страница 2: ...ich are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service yo...

Страница 3: ...ide owners users operators lessors and lessees with the precautions and operating proce dures essential for the safe and proper machine operation for its intended purpose Due to continuous product imp...

Страница 4: ...EATH THIS DECAL WILL HAVE AN ORANGE BACKGROUND INDICATES A POTENTIALITY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL...

Страница 5: ...DIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PROD...

Страница 6: ...ION LOG 4 JLG Lift 3121272 REVISION LOG Original Issue A January 10 2012 Revised B January 4 2013 Revised C April 8 2013 Revised D January 5 2015 Revised E May 26 2016 Revised F June 29 2018 Revised C...

Страница 7: ...LING 1 11 1 5 MAINTENANCE 1 11 Maintenance Hazards 1 11 Battery Hazards 1 12 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 1 PERSONNEL TRAINING 2 1 Operator Training 2 1 Trainin...

Страница 8: ...3 9 PLATFORM RAILS FOLD DOWN PROCEDURE 3248RS 10RS AND 6RS CE ONLY 3 17 3 10 BATTERY CHARGING 3 20 Battery Charger Fault LED Flash 3 21 3 11 DC TO AC INVERTER OPERATION OPTION 3 22 3 12 PARKING AND ST...

Страница 9: ...1 DTC CHECK TABLE INDEX 5 17 5 12 DIAGNOSTIC TROUBLE CODES DTC CHECK TABLES 5 18 0 0 Help Comments 5 18 2 1 Power Up 5 19 2 2 Platform Controls 5 19 2 3 Ground Controls 5 20 2 5 Function Prevented 5 2...

Страница 10: ...se Location All Machines 3 29 3 21 Brake Manual Disengage 3 30 4 1 Location of Manual Descent Control 4 2 5 1 Hydraulic Oil Check Procedure All Machines 5 8 5 2 Battery Fluid Level 5 9 5 3 Wheel Lug N...

Страница 11: ...e to operate The owner user operator lessor lessee of the machine must not accept operating responsibility until this manual has been read training is accomplished and operation of the machine has bee...

Страница 12: ...achine is to be used in a manner which is within the scope of its intended application as determined by JLG All operating personnel must be familiar with the emer gency controls and emergency operatio...

Страница 13: ...n of these devices is a safety violation MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER Do not operate any machine on whic...

Страница 14: ...ving machine Remove all rings watches and jewelry when operating machine Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment Persons under th...

Страница 15: ...he lanyard Attach only one 1 lanyard per lanyard anchorage point Enter and exit only through gate area Use extreme caution when entering or leaving platform Ensure that the platform assembly is fully...

Страница 16: ...ols and their equipment from any electrical line or apparatus carrying up to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less The minimum approach dista...

Страница 17: ...the platform in the elevated position Before driving on floors bridges trucks and other surfaces check allowable capacity of the surfaces Never exceed the maximum work load as specified on the platfo...

Страница 18: ...motionvisibleinsmoke 2 4 7 1 6 3 3 Lightbreeze Windfeltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperrais...

Страница 19: ...or attachments If the scissor arm assembly or platform is caught so that one or more wheels are off the ground all persons must be removed before attempting to free the machine Use cranes forklift tru...

Страница 20: ...nces in all drive speeds When driving in high speed switch to low speed before stopping Travel grades in low speed only Do not use high speed drive in restricted or close quarters or when driving in r...

Страница 21: ...rict attention to these precautions to avoid possible injury to personnel or damage to the machine or property A maintenance program must be established by a qualified person and must be fol lowed to...

Страница 22: ...M SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER Battery Hazards Always disconnect batteries when servicing electrical com ponents or when performing welding on the machine Do...

Страница 23: ...ground emergency controls and safety features Control labels instructions and warnings on the machine Rules of the employer and government regulations Use of approved fall protection equipment Enough...

Страница 24: ...either the machine or the job site NOTE The Manufacturer or Distributor will provide qualified people for training assistance with the first unit s deliv ered and from that time forward as requested...

Страница 25: ...iodofmorethan3 months orPurchasedused Owner Dealer orUser QualifiedJLG Mechanic ServiceandMaintenanceManualand applicableJLGinspectionform AnnualMachine Inspection seenotebelow Annually nolaterthan13m...

Страница 26: ...peration and Safety Manuals Ensure that a copy of the Operation and Safety Manual AEM Safety Man ual ANSI markets only and ANSI Manual of Responsi bilities ANSI markets only is enclosed in the weather...

Страница 27: ...clean and unobstructed Check that gate closes prop erly and is not bent or damaged During operation keep gate closed 11 Lanyard Anchorage Points JLG Industries Inc rec ommends personnel in the platfor...

Страница 28: ...ol switches return to neutral position emergency stop switch functions properly Control markings legible 3 Hydraulic Pump Motor Control Valve Installation No unsupported wires or hoses no damaged or b...

Страница 29: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121272 JLG Lift 2 7 Figure 2 1 Daily Walk Around Inspection Side Covers Removed All Machines 1 2 3 5 7 6 8 9 10 11 4 8 1 1 1...

Страница 30: ...switch operation e With the platform elevated on a smooth firm level surface with no overhead obstructions drive the machine to check if the high drive cutout speed limit is engaged at the height indi...

Страница 31: ...be fully lowered stowed to drive out of tilt condition Table 2 3 Tilt Activation Setting MODEL TILT SETTING front to back TILT SETTING side to side 1932RS 6RS ALL 3 1 5 3248RS 10RS ANSI CSA JPN 3 2 3...

Страница 32: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 10 JLG Lift 3121272 NOTES...

Страница 33: ...CRIPTION This machine is a self propelled aerial work platform on top of an elevating scissor arm mechanism The Lift s intended pur pose is to position personnel with their tools and supplies at posit...

Страница 34: ...ng personnel of potential hazards constituted by the operating characteristics and limitations of the machine See foreword for definitions of placard safety signal words 3 4 PLATFORM LOADING The platf...

Страница 35: ...3 3 3 5 MACHINE CONTROL LOCATIONS 1 Ground Control Station 2 Platform Control Station 3 Platform Manual Descent Control 4 AC Plug To Platform AC Receptacle Outlet Box 5 AC Plug Battery Charger Input...

Страница 36: ...4 JLG Lift 3121272 1 Ground Control Station 2 Platform Control Station 3 Platform Manual Descent Control 4 AC Plug To Platform AC Receptacle Outlet Box 5 AC Plug Battery Charger Input Plug Figure 3 2...

Страница 37: ...pulling the switch out and is turned off by depressing switch A two position red mushroom shaped emergency stop switch when positioned to ON with the key selector switch positioned to ground furnishe...

Страница 38: ...Battery Discharge Indicator BDI an LCD display which shows the current hour meter reading or Diagnostic Trouble Code s DTC when a functional problem occurs with the machine and a system distress LED W...

Страница 39: ...oaded NOTE CE Australia Japan ANSI Export If the Overload Indi cator is illuminated all platform controls are prevented unless the platform has been raised less than 9 84 ft 3m then lift down only is...

Страница 40: ...he machine just in front of the drive wheel The lowering procedure is as follows 1 Locate the manual descent control T handle See Figure 3 5 KEEP HANDS AND ARMS OUT OF THE PATH OF THE SCISSOR ARMS AND...

Страница 41: ...oystick Control 3 Trigger Switch 4 Forward Reverse Lift Lower Direction Decal 5 Alarm 6 Overload Indicator If Equipped 7 Machine Tilt Indicator 8 Emergency Stop Switch 9 Horn Button 10 Drive and Lift...

Страница 42: ...Drive functions the joystick control must be returned to the neutral position for approximately 1 2 second before the function change is operable This toggle switch is used to select operation of eith...

Страница 43: ...is proportionally con trolled by the distance from the neutral center position of the joystick controller NOTE If the machine is equipped with a footswitch Japanese Specification Only the footswitch...

Страница 44: ...one at the platform and one at the ground control station to the ON posi tion Steering Item 2 Figure 3 7 On the platform control station position the lift drive select switch to the drive position To...

Страница 45: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3121272 JLG Lift 3 13 Figure 3 8 Grade and Sideslope Definition HORIZONTAL LEVEL GRADE SIDESLOPE...

Страница 46: ...If equipped If the machine is equipped with electronic arm guards the plat form will stop lowering at a predetermined height lowering can continue after a three 3 second delay Once the lowering func...

Страница 47: ...ite personnel when the machine is operating in the area Low Battery Charge and System Fault Indicator Item 11 Figure 3 6 This indicator light comes on and stays lit when the battery charge level is ve...

Страница 48: ...o extend the deck 1 Pull up on the locking pin 1 on left side mid rail near the front of the machine Rotate pin 90 to hold in up position 2 Grasp the top handrails 2 of the extendible deck and push th...

Страница 49: ...ck extension top rail pins must be removed and deck extension top side rails slid towards rear of machine before lowering side rails Place pins back in the extension side top rails before folding main...

Страница 50: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 18 JLG Lift 3121272 Figure 3 10 Platform Rails Fold Down Sequence 3248RS 10RS Only 1 1 3 3 2 2 4 4...

Страница 51: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3121272 JLG Lift 3 19 Figure 3 11 Platform Rails Fold Down Sequence 6RS CE Only 1 1 3 3 2b 2a 2 4 4...

Страница 52: ...ne 2 Connect the charger AC input plug to a grounded out let using a 3 wire heavy duty extension cord See Table 5 6 Electrical System Specifications on page 5 6 for battery charger AC input specificat...

Страница 53: ...y charger can be found in the charger manufac turers Owner s Guide Table 3 1 Battery Charger Fault LED Flash FLASHING LED FAULT REMEDY AMBER BatteryHighVoltage Uponbatteryvoltage 2 5Vpercell startup c...

Страница 54: ...connecting to inverter AC cir cuit Connect devices one at a time to the AC receptacle box Do not connect to many high surge devices at once NOTICE IF INVERTER SWITCH IS LEFT ON AND EMERGENCY STOP BUT...

Страница 55: ...he machine and prevent unauthorized use NOTE For added protection the platform control station can be secured to it s mounting plate see Figure 3 14 4 At the ground control station depress emergency s...

Страница 56: ...ugh to allow the safety prop to be engaged on the lift cylinder rod 2 Pull out up on the stop handle to release the safety prop locking pin 3 Rotate the prop assembly until it rests on the lift cylin...

Страница 57: ...CONTROLS INDICATORS AND OPERATION 3121272 JLG Lift 3 25 PropEngaged PropReleasedandLocked Figure 3 15 1932RS 6RS Scissor Arm Safety Prop PropEngaged PropReleasedandLocked Figure 3 16 3248RS 10RS Sciss...

Страница 58: ...fted using a spreader bar and four equal length straps or chains capable of supporting the full gross weight of the machine see Figure 3 18 Lift only using the lifting lugs provided at the four corner...

Страница 59: ...HINE CONTROLS INDICATORS AND OPERATION 3121272 JLG Lift 3 27 Figure 3 18 Lifting Using Spreader Bar and Lift Lug Locations All Machines 1 Four 4 equal length chains or lifting straps 2 Spreader Bar As...

Страница 60: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 28 JLG Lift 3121272 Figure 3 19 Tie Down and Lift Lug Locations All Machines...

Страница 61: ...h tow vehicle 2 Turn power on in ground mode on the ground con trol station 1 3 The brake release switch 2 is located inside the hydraulic components side cover remove cover to access the switch 4 Dep...

Страница 62: ...er bolts 3 in the disengage holes and the brake on that drive motor will disen gage 5 Repeat this procedure on opposite wheel drive With both drive motor brakes now disengaged the machine can be moved...

Страница 63: ...cupant s prior to freeing the machine Righting of Tipped Machine A fork truck of suitable capacity or equivalent equipment should be placed under the elevated side of the chassis with a crane or other...

Страница 64: ...productsafety jlg com Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular...

Страница 65: ...ation and maintenance of this machine The maintenance portion of this section is intended as informa tion to assist the machine operator to perform daily mainte nance tasks only and does not replace t...

Страница 66: ...veSpeed Stowed Elevated 2 5mph 4kph 0 3mph 0 5kph MaximumStowedTravelGrade Gradeability ReferenceFigure 3 8 onpage 3 13 25 14 InsideTurningRadius 23 6in 0 6m 47 2in 1 2m OutsideTurningRadius 84 4in 2...

Страница 67: ...b 832kg 2 070lb 940kg CHASSIS continued GroundBearingPressure ANSI CSA JPN CE 130PSI 9 18 kg cm2 81PSI 5 69kg cm2 108PSI 7 6kg cm2 GroundClearance ChassisBasePlate 3in 76 2mm 4in 102mm MaximumHydrauli...

Страница 68: ...ax Capacity MAXIMUM OPERATING WIND SPEED ANSI CSA JPN 1932 500Lb 227Kg 250Lb 113Kg 2 100Lb 445N 28mph 3248 705Lb 320Kg 250Lb 113Kg 2 100Lb 445N 28mph ANSIEXPORT 1932 480Lb 218Kg 240Lb 109Kg 2 100Lb 44...

Страница 69: ...00cm 54 75in 139cm WorkingHeight 25ft 7 6m 38ft 11 5m RailHeight PlatformFloortoTopofRail 40in 101 6cm 41in 104 3cm ANSI 43 6in 110 7cm CE RailHeight Folded GroundtoMidRail 69 3in 176cm CEONLY 78 3in...

Страница 70: ...System Specifications DESCRIPTION ALL MACHINES ElectricalSystemVoltage DC 24V BatteryCharger 1001129847 Input ACInputVoltage NominalACInputVoltage InputFrequency Max ACInputCurrent IngressProtection O...

Страница 71: ...parable vis cosities Table 5 7 Critical Stability Weights COMPONENT 1932RS 6RS 3248RS 10RS WheelandTireAssembly each Front Rear 21 6lb 9 8kg 21 6lb 9 8kg 43lb 19 5kg 40 5lb 18 4kg Wheel Tire and Drive...

Страница 72: ...cMIL L 2105 HO JLGRecommends MobilDTE10EXCEL15 ATF AutomaticTransmissionFluid MobilEALENVIRONSYNH32 MobilEALHYDRAULICOIL32 Table 5 11 Hydraulic Oil Specifications SPECIFICATION MOBIL DTE 10 EXCEL 15 M...

Страница 73: ...ulic reservoir by looking at the mark ings on the side The reservoir is marked with a MAX maximum marking 3 The oil level must be kept at or within one 1 inch of this marking to operate prop erly 2 If...

Страница 74: ...L VENTI LATED AREA ADD ONLY DISTILLED WATER TO BATTERIES WHEN ADDING DISTILLED WATER TO THE BATTERIES A NON METALLIC CONTAINER AND OR FUNNEL MUST BE USED Check the electrolyte level of the batteries o...

Страница 75: ...same size and brand as originally installed on the machine or offered by JLG as an approved replacement Please refer to the JLG Parts Manual for the part number of the approved tires for a partic ula...

Страница 76: ...r manently deforming the mounting holes in the wheel The proper procedure for attaching wheels is as follows 1 Start all lug nuts by hand to prevent cross threading DO NOT use a lubricant on threads o...

Страница 77: ...AND MAINTENANCE 3121272 JLG Lift 5 13 5 8 DECAL INSTALLATION Figure 5 4 Machine Decal Installation All Machines 3 1 2 5 6 7 9 10 11 12 13 14 16 17 19 21 20 22 24 25 1932 6RS 25 3248 10RS 8 15 4 13 14...

Страница 78: ...3819 1703819 1703819 1703819 6 1703822 1703822 1703822 1703822 1703822 1703822 1703822 7 1704016 1704016 1704016 1704016 1704016 1704016 1704016 8 1704277 1704277 1704277 1704277 1704277 1704277 17042...

Страница 79: ...1932RS 6RS 1001132364 3248RS 10RS 1705699 1932RS 6RS 1001132364 3248RS 10RS 1705699 1932RS 6RS 1001132364 3248RS 10RS 1705699 1932RS 6RS 1001132364 3248RS 10RS 1705699 1932RS 6RS 1001146903 3248RS 10...

Страница 80: ...2 1703072 1703072 1703072 24 1705719 SPA 1705719 POR 3253098 CAN 1705945 CHI 1706053 KOR 25 1703464 1703464 1703464 1703464 1703464 1703464 3252507 26 1705303 CSA NOTE Reference applicable Illustrated...

Страница 81: ...stic analyzer To troubleshoot multiple DTCs start with the DTC with the higher first two digits If a correction is made during a check conclude the check by cycling the machine power off then back on...

Страница 82: ...ounted ReferproblemtoaqualifiedJLGmechanic 005 DRIVE LIFTUPPREVENTED TILTED ELEVATED Drivingisnotpossiblesincetheplatformis elevatedandthechassisisnotlevel Check that the machine is tilted If so lower...

Страница 83: ...witch for visible damage ReferproblemtoaqualifiedJLGmechanic 224 FUNCTIONPROBLEM STEERLEFTPER MANENTLYSELECTED Thesteerleftswitchwasclosedduringpower upinplatformmode Check if the steer left switch is...

Страница 84: ...232 FUNCTIONPROBLEM DRIVE LIFT BOTHOPEN Thedriveandliftinputsarebothde energized inplatformmode Check if either function is active if Yes Refer problem to a qualified JLG mechanic 2 2 Platform Control...

Страница 85: ...asured platformloadisexcessive Remove excess weight from the platform Check that platform is not caught on something preventing up or down movement ReferproblemtoaqualifiedJLGmechanic 258 DRIVE LIFTPR...

Страница 86: ...LINECONTACTORMISWIREDONOR WELDED Thereisaproblemwiththelinecontactor ReferproblemtoaqualifiedJLGmechanic 326 AUXILIARYRELAY SHORTTOBATTERY Thereisaproblemwiththeauxiliaryrelaycon tactsorwiring Referpr...

Страница 87: ...oblemtoaqualifiedJLGmechanic 3315 RIGHTBRAKEOPENCIRCUIT Aproblemhasbeendetectedinthisfunction ReferproblemtoaqualifiedJLGmechanic 3349 LINECONTACTORCOIL SHORTTO GROUND Aproblemhasbeendetectedinthisfun...

Страница 88: ...Gmechanic 3 3 Ground Output Driver DTC FAULT MESSAGE DESCRIPTION CHECK 4 2 Thermal Limit SOA DTC FAULT MESSAGE DESCRIPTION CHECK 421 POWERMODULETOOHOT PLEASE WAIT Thepowermodulehasreachedthermalcut ou...

Страница 89: ...oper battery charging or incorrect voltage batteries being used ReferproblemtoaqualifiedJLGmechanic 446 4421 4422 LOGICSUPPLYVOLTAGEOUTOFRANGE TheSystemModulelogicsupplyvoltagewas measuredtobeoutofnor...

Страница 90: ...rmoduledetectedaprobleminthe drivemotors powercircuitwiring ReferproblemtoaqualifiedJLGmechanic 776 STALLEDPUMPMOTORORPOWER WIRINGERROR Thepowermoduledetectedaprobleminthe drivemotors powercircuitwiri...

Страница 91: ...ists ReferproblemtoaqualifiedJLGmechanic 7 7 Electric Motor DTC FAULT MESSAGE DESCRIPTION CHECK 8 2 LSS Load Sensing System DTC FAULT MESSAGE DESCRIPTION CHECK 8212 LSSPRESSURESENSOR DISAGREEMENT Pres...

Страница 92: ...problemtoaqualifiedJLGmechanic 8 2 LSS Load Sensing System DTC FAULT MESSAGE DESCRIPTION CHECK 8 4 Elevation Switch DTC FAULT MESSAGE DESCRIPTION CHECK 84109 ELEVATIONSWITCHCONTACTSDIS AGREEMENT Theel...

Страница 93: ...SET TINGS ThecontrolsystemdetectedanEEPROMfail ure ReferproblemtoaqualifiedJLGmechanic 999 FUNCTIONLOCKEDOUT POWERMOD ULESOFTWAREVERSIONIMPROPER Thepowermodulesoftwareversionisnot compatiblewiththeres...

Страница 94: ...9957 9958 9960 9962 9963 9964 9969 9970 9971 99143 99144 99145 99146 99147 99148 99149 POWERMODULEFAILURE INTERNAL ERROR Aproblemhasbeendetectedwiththepower module Cyclemachinepoweron offafewtimesifth...

Страница 95: ...ECTION 6 INSPECTION AND REPAIR LOG 3121272 JLG Lift 6 1 SECTION 6 INSPECTION AND REPAIR LOG MachineSerialNumber_______________________________________ Table 6 1 Inspection and Repair Log DATE COMMENTS...

Страница 96: ...SECTION 6 INSPECTION AND REPAIR LOG 6 2 JLG Lift 3121272 Table 6 1 Inspection and Repair Log DATE COMMENTS...

Страница 97: ......

Страница 98: ...CorporateOffice JLGIndustries Inc 1JLGDrive McConnellsburg PA17233 9533USA 717 485 5161 Corporate 877 554 5438 CustomerSupport 717 485 6417 Visit our website for JLG Worldwide Locations www jlg com...

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