JLG 1930ES, 2030ES, 2630ES, 2646ES, 3246ES Scissor Lift Service Manual
218 pages · Publication 3121166
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What's inside
From the manual's own table of contents: 271 sections, 336 entries. See sample pages (PDF, 661 KB)
General
Hydraulic System Safety
Maintenance1 topic
- Specifications
Capacities
Fluid Capacities
Tires
Batteries
Motors
Battery Charger
Travel Speed
Lift Speed (No Load in Platform)
Model Dimensions2 topics
- Torque Requirements
- Lubrication
Hydraulic Oil1 topic
- Limit Switches
Tilt Alarm
High Drive Speed Cutout
Pressure Settings5 topics
- Cylinder Specifications
- Major Component Weights
- Critical Stability Weights
- Torque ChartS
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Components Removal and Installation
Show all 271 sections
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing2 topics
- Lubrication and Information
- TABLE OF CONTENTS Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift Test
Platform Drift
Cylinder Drift5 topics
- Pins and Composite Bearing Repair Guidelines
- Preventive Maintenance and Inspection Schedule
- Diagnostic Port
- MDI (Multifunction Digital Indicator) and brake release
- Traction System
Theory of Operation1 topic
- Torque Hub
Roll Test
Leak Test
Oil Check/Fill Procedure
Manual Disengage Procedure
Motor and Brake Disassembly
Motor Disassembly
Drive Motor Removal
Main Gearbox Disassembly
Input Carrier Disassembly
Hub Disassembly
Spindle Disassembly
Spindle Sub-Assembly
Hub Sub-Assembly
Input Carrier Sub-Assembly
Main Gearbox Assembly
Motor and Brake Assembly
Motor Assembly
Tightening and Torquing Bolts
Assembly Tools1 topic
- Electric Drive Motor
Disassembly
Replacing Motor Bearing
Inspecting Motor Brushes
Replacing Motor Brushes
Replacing the Motor Cable
Reassembling the Motor
Motor Maintenance
Inspection and Service
Reassembly
Drive Motor Troubleshooting
Drive Motor Disassembly
Drive Motor Inspection and Service
Drive Motor Reassembly
Drive Motor Servicing Guidelines1 topic
- Drive Motor Electrical Evaluation
Servicing Guidelines
Common Traction System Difficulties1 topic
- TABLE OF CONTENTS Power Module - Sevcon
Power Module Electrical Evaluation1 topic
- Power Module - ZAPI
ZAPI Power Module Electrical Evaluation1 topic
- Battery Removal
Battery Maintenance and Safety Practices1 topic
- Battery Charger
Battery Charger Maintenance
Battery Charger Troubleshooting1 topic
- Battery Charger/Inverter (Option)
Battery Charger/Inverter Troubleshooting2 topics
- Drive Motor Cable Routing
- Pothole Switch Replacement
Rotary Angle Sensor Replacement1 topic
- Ground Control Station
Printed Circuit Board (PCB) Replacement
Tilt Sensor Replacement4 topics
- Arms and Platform Positioning and Support
- Platform Removal
- Scissor Arms Removal
- Platform Control Station
Joystick Controller2 topics
- Cylinders - Theory of Operation
- Valves - Theory of Operation
Solenoid Control Valves (Bang-Bang)
Relief Valves
Crossover Relief Valves
Proportional Valve
Manual Descent Valve1 topic
- Cylinder Checking Procedure
Cylinders Without Counterbalance Valves and Steer Cylinder2 topics
- Lift Pressure Setting Procedure
- Hydraulic Oil Fill
Oil Check Procedure
Slide Block Lubrication2 topics
- Lift Cylinder Removal
- Pump/Motor
Pump Motor Electrical Evaluation
Pump Removal
Motor Removal1 topic
- Cylinder Repair
Steer Cylinder Piston Removal - Cyl. p/n-1684456
Cleaning and Inspection
Assembly1 topic
- Hand Held Analyzer
To Connect the Hand Held Analyzer
Using the Analyzer
Changing the Access Level of the Hand Held Analyzer
Adjusting Parameters Using the Hand Held Analyzer
Machine Setup1 topic
- Tilt Sensor Calibration
Ground Module Software Version 1.51 topic
- TABLE OF CONTENTS Ground Module Software Version 1.4
Failure Troubleshooting for The Field2 topics
- Tilt Sensor Electrical Evaluation
- Elevation Angle Sensor Electrical Evaluation
Tilt vs. Allowed Height Evaluation10 topics
- Elevation Sensor Calibration
- Updating Software
- Troubleshooting
- Machine Model Adjustment - SEVCON - 1600346 Power Module
- Machine Model Adjustment - ZAPI - 1001092456 Power Module
- Machine Configuration Programming Information - SEVCON - 1600346
- Machine Configuration Programming Information - ZAPI - 1001092456
- Introduction
- DTC Index
- DTC Check Tables
0-0 Help Comments
2-1 Power-Up
2-2 Platform Controls
2-3 Ground Controls
2-5 Function Prevented
3-1 Line Contactor Open Circuit
3-2 Line Contactor Short Circuit
3-3 Ground Output Driver
4-2 Thermal Limit (SOA)
4-4 Battery Supply
6-6 Communication
6-7 Accessory
7-7 Electric Motor
8-1 Tilt Sensor
8-2 Platform Load Sense
9-9 Hardware2 topics
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Continuity Measurement Over Long Distances
Requirements
Procedure1 topic
- Applying Silicone Dielectric Compound To Amp Connectors
Wedge Lock
Service - Voltage Reading1 topic
- Working With Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly1 topic
- Switches
Basic check1 topic
- TABLE OF CONTENTS Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side3 topics
- Circuit Boards: Inputs and Outputs
- Electrical Schematics and Layouts
- Hydraulic Schematic
Torque Chart (SAE Fasteners - Sheet 1 of 7)
Torque Chart (SAE Fasteners - Sheet 2 of 7))
Torque Chart (SAE Fasteners - Sheet 3 of 7)
Torque Chart (SAE Fasteners - Sheet 4 of 7)
Torque Chart (METRIC Fasteners - Sheet 5 of 7))
Torque Chart (METRIC Fasteners - Sheet 6 of 7)
Torque Chart (METRIC Fasteners - Sheet 7 of 7)
Diagnostic Port
MDI Installation/Removal
Traction Control Circuit - Sevcon Power Module
Traction Control Circuit - ZAPI Power Module
Disengage Procedure
Motor & Brake Disassembly
Drive Motor Assembly
Assembly Tool 1
Assembly Tool 2
Assembly Tool 3
Drive Motor
Motor Side
Motor Front
Bearing Pressure Guidelines
Terminal Tightening
Drive Motor Components
Wire Harness Connections
Sevcon Power Module Location
ZAPI Power Module Location
Battery Fluid Level
Battery Charger Location
Battery Charger/Inverter Location
Battery Charger/Inverter
Motor Cable Routing (1930ES)
Motor Cable Routing (2030ES/2630ES)
Limit Switch Locations - 1 of 2
Limit Switch Locations - 2 of 2
Pothole Switch Adjustment - 1930ES/2030ES/2630ES
Pothole Switch Adjustment - 2630ES/3246ES
Tilt Sensor Location
Tilt Sensor Removal
Arms and Platform Positioning and Support
Joystick
Lift Pressure Setting
LIft Cylinder Removal
Cylinder Barrel Support
Cylinder Rod Support
Gar-Max Bearing Installation
Rod Seal Installation
Poly-Pak Piston Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Piston Seal Kit Installation
Rod Assembly Installation
Lift Cylinder/Pump/Tank Assembly
Lift Cylinder Assembly
Hand Held Analyzer
Analyzer Flow Chart - Sheet 1 of 3
Analyzer Flow Chart - Sheet 2 of 3
Analyzer Flow Chart - Sheet 3 of 3
Voltage Measurement (DC)
Resistance Measurement
Continuity Measurement
Current Measurement (DC)
AMP Connector
Connector Assembly (1 of 4)
Connector Assembly (2 of 4)
Connector Assembly (3 of 4)
Connector Assembly (4 of 4)
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Electrical Schematic - 1870164 G - Sheet 1 of 2
Electrical Schematic - 1870164 G - Sheet 2 of 2
Electrical Schematic - 187205 B - Sheet 1 of 2
Electrical Schematic - 187205 B - Sheet 2 of 2
Electrical Schematic - Sheet 1 of 2 (Machines with MDI)
Electrical Schematic - Sheet 2 of 2 (Machines with MDI)
Battery Inverter/Charger Schematic
Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 1 of 3
Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 2 of 3
Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 3 of 3
Electrical Components - Sheet 1 of 2
Electrical Components - Sheet 2 of 2
Electrical Components - Sheet 1 of 2 (Machines with MDI)
Electrical Components - Sheet 2 of 2 (Machines with MDI)
Electrical Components - (Machines with 1001092456 Power Module) - Sheet 1 of 2
Electrical Components - (Machines with 1001092456 Power Module) - Sheet 2 of 2
Hydraulic Schematic - 2792599-D
Operating Specifications
Tire Specifications
Lift Speed
Dimensions
Torque Requirements
Hydraulic Oil Specifications (Standard)
Tilt Settings
High Drive Speed Cutout Height
Cylinder Specifications
Major Component Weights
Critical Stability Weights
Inspection and Maintenance
Preventive Maintenance and Safety Inspection
Sevcon Power Module Specs
ZAPI Power Module Specs
Battery Charger Specs
Battery Algorithms
Battery Charger/Inverter Specs
Tilt Sensor Harness Chart
Tilt Sensor Harness for 4000021
Tilt Sensor Harness for 1001114936
Joystick Specifications
Connector Chart
Lift Pressure Settings
Cylinder Piston Nut Torque Specifications
Holding Valve Torque Specifications
Valve Torque Values
Flash Code Listing
Machine Model Adjustment - (Machines with Sevcon - 1600346 Power Module Only)
Machine Model Adjustment - (Machines with ZAPI - 1001092456 Power Module Only)
(Machines with Sevcon - 1600346 Power Module Only)
(Machines with ZAPI - 1001092456 Power Module Only)
Ground Board J1 (1600346 Power Module ONLY)
Ground Board J2
Ground Board J3
Platform Board J1
Platform Board J3
Platform Board J4
Power Module (1600346 Power Module ONLY)
Power Module - J1 (1001092456 Power Module ONLY)
Power Module - J2 (1001092456 Power Module ONLY)
Inside this manual
Real pages from this service manual (218 pages). Open the sample pages (PDF, 660 KB)
- Specifications, page 20: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 140: SECTION 5 - JLG CONTROL SYSTEM
- Diagram, page 191: SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 93: SECTION 3 - CHASSIS & SCISSOR ARMS
- Color page, page 112: SECTION 4 - HYDRAULICS
Other manuals for this machine
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 218 pages
Quantity one is the manual described above.
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Other editions and similar models
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