Jlg 3248RS/10RS Service Manual manuals

Jlg 3248RS/10RS Service Manual User Manual (150 pages)

Brand: Jlg | Category: Special machinery | Size: 7.27 MB |

English

Table of contents

1932RS/6RS

1

3248RS/10RS

1

PRECAUTIONS

3

REVISION LOG

4

10

SECTION 1. SPECIFICATIONS

13

Dimensional Data

14

Batteries

14

Electrical System Motors

15

Travel Speed

15

Lift Speed

15

SECTION 1 - SPECIFICATIONS

16

High Drive Speed Cutout

17

1.5 CYLINDER SPECIFICATIONS

17

1.6 MAJOR COMPONENT WEIGHTS

17

1.7 TORQUE REQUIREMENTS

17

Torque Charts

18

SOCKET HEAD CAP SCREWS

20

Magni Coating (Ref 4150701)*

24

SECTION 2. GENERAL

25

INSPECTION SCHEDULE

26

SECTION 2 - GENERAL

27

Changing Hydraulic Oil

31

Lubrication Specifications

31

2.5 CYLINDER DRIFT TEST

31

Platform Drift

31

Cylinder Drift

31

GUIDELINES

32

3.1 MACHINE COMPONENT COVERS

33

Battery Quick-Disconnect

34

(If Equipped)

34

3.3 BATTERY CHARGER

35

3.4 BATTERY CHARGING

36

Battery Charger Maintenance

37

3-6 – JLG Lift – 3121273

38

Inverter Location on Machine

39

Inverter Operation

40

Inverter Troubleshooting

40

Inverter Specifications

40

3.6 GROUND CONTROL STATION

41

Components Location

41

Removal (All Models)

41

Installation

41

Location

42

Switch Adjustment

43

LOCATION

44

3.10 TILT SENSOR REPLACEMENT

44

Tilt Sensor Removal

45

Tilt Sensor Installation

45

3.11 TRACTION SYSTEM

46

3121273 – JLG Lift – 3-15

47

3-16 – JLG Lift – 3121273

48

3121273 – JLG Lift – 3-17

49

P/N - 1001139845

50

3.13 DRIVE MOTOR SERVICING

51

Drive Motor Troubleshooting

51

Servicing Guidelines

51

3-20 – JLG Lift – 3121273

52

Drive Motor Removal

53

Drive Motor Disassembly

54

Drive Motor Reassembly

55

3-24 – JLG Lift – 3121273

56

Drive Motor Installation

57

3.14 TORQUE HUB SERVICING

58

Roll Test

58

Leak Test

58

Oil Check/Fill Procedure

58

Main Gearbox Disassembly

59

Input Carrier Disassembly

60

Hub Disassembly

61

Spindle Disassembly

62

Tightening and Torquing Bolts

63

Assembly Tools

63

Spindle Assembly

64

Hub Assembly

65

Input Carrier Assembly

66

Main Gearbox Assembly

67

3-36 – JLG Lift – 3121273

68

3121273 – JLG Lift – 3-37

69

3-38 – JLG Lift – 3121273

70

3121273 – JLG Lift – 3-39

71

3-40 – JLG Lift – 3121273

72

3121273 – JLG Lift – 3-41

73

3-42 – JLG Lift – 3121273

74

3121273 – JLG Lift – 3-43

75

3-44 – JLG Lift – 3121273

76

3121273 – JLG Lift – 3-45

77

3.19 PLATFORM CONTROL STATION

78

Installation/Removal

78

Scissor Arms

78

Control Station Disassembly

78

1001132362 B

79

Joystick Controller

80

SECTION 4. HYDRAULICS

81

4.3 PUMP/MOTOR

82

Hydraulic Oil Check Procedure

83

Pump/Tank Disassembly

84

Pump Motor Removal

84

3121273 – JLG Lift – 4-5

85

SECTION 4 - HYDRAULICS

86

4.6 LIFT CYLINDER REMOVAL

87

4.7 CYLINDER REPAIR

88

Steer Cylinder Piston Removal

89

Cleaning and Inspection

89

3121273 – JLG Lift – 4-11

91

5.1 HAND HELD ANALYZER

97

Diagnostic Port

97

Using the Analyzer:

98

Analyzer:

99

Analyzer

100

Machine Setup

100

Joystick Calibration

101

Updating Software

101

JLG Analyzer

102

Interface

102

5.2 MACHINE MODEL ADJUSTMENT

109

5-14 – JLG Lift– 3121273

110

6.1 INTRODUCTION

111

System Fault/DTC Indication

111

6.3 X-CONNECTOR REFERENCES

111

6.4 DTC INDEX

112

6.5 DTC CHECK TABLES

115

0-0 Help Comments

115

2-1 Power-Up

115

2-2 Platform Controls

115

2-3 Ground Controls

117

2-5 Function Prevented

117

3-3 Ground Output Driver

119

4-2 Thermal Limit (SOA)

122

4-4 Battery Supply

122

6-6 Communication

123

7-7 Electric Motor

123

8-4 Elevation Switch

125

9-9 Hardware

125

3121273 – JLG Lift – 7-1

127

7-2 – JLG Lift – 3121273

128

3121273 – JLG Lift – 7-3

129

Requirements:

130

Procedure

130

3121273 – JLG Lift – 7-5

131

Assembly

132

Disassembly

133

Wedge Lock

134

Service - Voltage Reading

135

DT/DTP Series Assembly

136

DT/DTP Series Disassembly

136

HD30/HDP20 Series Assembly

136

HD30/HDP20 Series Disassembly

137

7.5 SWITCHES

138

Basic check

138

Limit Switches

138

Automatic Switches

139

7-14 – JLG Lift – 3121273

140

3121273 – JLG Lift – 7-15

141

1001129844_D - Sht. 2

142

1001129844_D - Sht. 3

144

7-20 – JLG Lift – 3121273

146

3121273 – JLG Lift – 7-21

147

1001131095_E

148

BATTERY WARNING

149

JLG Worldwide Locations

150

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