JLG 2632R User manual

Service & Maintenance Manual
Models
2632R
3246R
3121788
April 12, 2019 - Rev B
AS/NZS GB
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SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
3121788 A
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
GENERAL
This section contains the general safety precautions which
must be observed during maintenance of the Mobile Ele-
vating Work Platform (MEWP). It is of utmost importance
that maintenance personnel pay strict attention to these
warnings and precautions to avoid possible injury to
themselves or others, or damage to the equipment. A
maintenance program must be followed to ensure that
the machine is safe to operate.
MODIFICATION OR ALTERATION OF A MEWP SHALL BE MADE ONLY
WITH WRITTEN PERMISSION FROM THE MANUFACTURER.
The specific precautions to be observed during mainte-
nance are inserted at the appropriate point in the manual.
These precautions are, for the most part, those that apply
when servicing hydraulic and larger machine component
parts.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER
THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA
RESPONSIBILITY OF THE OWNER/OPERATOR.
HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems
operate at extremely high potentially dangerous pres-
sures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any por-
tion of the system.
MAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SEC-
TION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR
DEATH AND IS A SAFETY VIOLATION.
•USE ONLY REPLACEMENT PARTS OR COMPONENTS
THAT ARE APPROVED BY JLG. TO BE CONSIDERED
APPROVED, REPLACEMENT PARTS OR COMPONENTS
MUST BE IDENTICAL OR EQUIVALENT TO ORIGINAL
PARTS OR COMPONENTS.
•NO SMOKING IS MANDATORY. NEVER REFUEL DURING
ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS
CLOSED AND SECURE AT ALL OTHER TIMES.
•REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN
PERFORMING ANY MAINTENANCE.
•DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE
APT TO BECOME CAUGHT ON OR ENTANGLED IN
EQUIPMENT.
•OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS
ON MACHINE AND IN SERVICE MANUAL.
•KEEP OIL, GREASE, WATER, ETC. WIPED FROM STAND-
ING SURFACES AND HAND HOLDS.
•USE CAUTION WHEN CHECKING A HOT, PRESSURIZED
COOLANT SYSTEM.
•NEVER WORK UNDER AN ELEVATED SCISSOR UNTIL
PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR
SAFETY PROP HAS BEEN ENGAGED.
•BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT OFF
ALL POWER CONTROLS.
•BATTERY SHOULD ALWAYS BE DISCONNECTED DUR-
ING REPLACEMENT OF ELECTRICAL COMPONENTS.
•KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
STOWED IN THEIR PROPER PLACE.
•USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
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SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
B3121788
REVISION LOG
Original Issue................................................... February 14, 2019
Revised............................................................... April 12, 2019
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3121788 i
TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-A
Hydraulic System Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-A
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-A
SECTION 1 - SPECIFICATIONS
1.1 Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Limit Switch Activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.5 Hydraulic Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.6 Hydraulic Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.7 Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.8 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.9 Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.10 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Service Maintenance Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.5 Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.6 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.7 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
SECTION 3 - CHASSIS & SCISSOR ARMS
3.1 Left and Right Side compartment components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Battery Removal/Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 DC/AC Power Inverter Installation - Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.5 Logic Control Module Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.6 Main Power Contactor Relay and pump control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.7 Pump Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.8 Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.9 Platform Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.10 Tilt Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.11 Arm Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.12 Pot-Hole Protection System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.13 Steer And Spindle Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.14 Arms and Platform Positioning and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.15 Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.16 Scissor Arms Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS
4.1 Cylinders - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Pump/Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 Hydraulic Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5 Hydraulic Pump and Electric motor assembly - 3246R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.6 Hydraulic Pump And Electric Motor Assembly - 2632R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.7 Hydraulic Manifold Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.8 Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.9 Hydraulic Brake Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.10 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.11 Pressure Setting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.12 Cylinder Checking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
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ii 3121788
TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.
4.13 Lift Cylinder Removal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.14 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.15 Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
SECTION 5 - JLG CONTROL SYSTEM
5.1 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Joystick Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3 Tilt Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4 Rotary Angle Sensor Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.5 Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6 Machine ConfiguRation Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.7 Machine Model Adjustment (PERSONALITY SETTINGS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
SECTION 6 - LSS (LOAD SENSING SYSTEM) SERVICE
6.1 LSS (Load Sensing System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Analyzer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Calibration Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4 Calibration And Verification Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5 Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.6 LSS Connector Pin Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.7 LSS Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
SECTION 7 - DIAGNOSTIC TROUBLE CODES
7.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Diagnostic Trouble Codes (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3 DTC Check Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.3 Applying Silicone Dielectric Compound to AMP Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Installation of Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.7 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.7 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
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3121788 iii
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Hydraulic Oil Operating Temperature Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-3. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1-4. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
2-1. Machine Component Locations - 3246R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-2. Machine Component Locations - 2632R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-3. Scissor Arm - Safety Prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-4. Scissor Arm - Safety Prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-5. Hydraulic Oil Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-6. Hydraulic Oil Fill Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3-1. Components on left Side Swing - Out Compartment Door (2632R and 3246R). . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2. Components on right Side Swing - Out Compartment Door (3246R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-3. Components on right Side Swing - Out Compartment Door (2632R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-4. Side Swing - Out Compartment Door Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-5. Battery Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-6. Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-7. DC/AC Power Inverter - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-8. Logic Module Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-9. Logic Module CO01 - Harness Connector Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-10. Hydraulic Pump Control - Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-11. Ground Control Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-12. Ground Control Station - Rear of Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-13. Platform Control Station Components (3246R) - External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-14. Platform Control Station Components (2632R) - External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-15. Platform Control Station Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-16. Platform Control Station Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-17. Platform Control Station Components (3246R) - Internal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-18. Platform Control Station Components (2632R) - Internal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-19. Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-20. Tilt Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-21. Angle Sensor Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-22. Pot-Hole Protection Assembly (3246R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-23. Pot-Hole Protection Assembly (2632R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-24. Steer and Spindle Assembly Installation (3246R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-25. Steer and Spindle Assembly Installation (2632R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-26. Drive Motor Cover Installation - Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-27. Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-28. Arms and Platform Positioning with Overhead Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-29. Platform Assembly - Installation/Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-30. Scissor Arm Assembly (3246R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-31. Scissor Arm Assembly - Pin Configuration (3246R). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-32. Scissor Arm Assembly (2632R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3-33. Scissor Arm Assembly - Pin Configuration (2632R). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3-34. Scissor Arm Assembly (3246R) - Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3-35. Scissor Arm Assembly (3246R) - Cable Routing (Coiled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3-36. Scissor Arm Assembly (3246R) - Cable Routing (With Foot Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3-37. Scissor Arm Assembly (3246R) - Cable Routing (Coiled) (With Foot Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3-38. Scissor Arm Assembly (2632R) - Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3-39. Scissor Arm Assembly (2632R) - Cable Routing (Coiled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3-40. Scissor Arm Assembly (2632R)- Cable Routing (With Foot Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3-41. Scissor Arm Assembly (2632R) - Cable Routing (Coiled) (With Foot Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
4-1. Hydraulic Pump - Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-2. Hydraulic Pump - Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3. Hydraulic Pump (3246R) - Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4. Hydraulic Pump (2632R) - Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
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iv 3121788
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
4-5. Hydraulic Manifold Assembly - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-6. Hydraulic Manifold Assembly - Schematic (1001215433) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-7. Hydraulic Manifold Assembly - Schematic (1001248679) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-8. Hydraulic Manifold Assembly - Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-9. Hydraulic Manifold Assembly - Component Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-10. Hydraulic Hose Routing (3246R). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4-11. Hydraulic Hose Routing (2632R). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-12. Drive Motor - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-13. Hydraulic Brake - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-14. Hydraulic Brakes - Manual Disengage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-15. LSS Pressure Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-16. Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-17. Steer Cylinder (3246R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4-18. Steer Cylinder (2632R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-19. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-20. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-21. Gar-Max Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4-22. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-23. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-24. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-25. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-26. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-27. Hydraulic Schematic (3246R) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4-28. Hydraulic Schematic (3246R) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4-29. Hydraulic Schematic (2632R) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4-30. Hydraulic Schematic (2632R) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
5-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-2. Diagnostic Port Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-3. Analyzer Menu - Help and Diagnostics (Version P1.10) - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-4. Analyzer Menu - System Test and Access Level (Version P1.10) - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-5. Analyzer Menu - Personalities and Machine Setup (Version P1.10) - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . 5-9
6-1. LSS Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
8-1. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8-2. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8-3. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8-4. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8-5. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8-6. Connector Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8-7. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8-8. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8-9. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8-10. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8-11. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8-12. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8-13. HD/HDP Unlocking Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8-14. Electrical Schematic - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8-15. Electrical Schematic - Sheet 2 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8-16. Electrical Schematic - Sheet 3 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8-17. Electrical Schematic - Sheet 4 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8-18. Electrical Schematic - Sheet 5 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8-19. Electrical Schematic - Sheet 6 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8-20. Electrical Schematic - Sheet 7 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
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3121788 v
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-4 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-5 Battery Charger Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-6 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-7 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-8 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-9 Biodegradable Hydraulic Fluid Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2-1 Inspection and Maintenance Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Preventive Maintenance & Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-3 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
3-1 Diagnostic Trouble Codes (Delta Q Battery Charger). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-2 Fault Codes (Green Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-3 Fault Codes (Eagle Battery Charger). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-4 Pump Control Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-5 Pump Power Module Terminal Functions (CO117-J1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-6 Joystick Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-7 Connector Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-8 Tilt Sensor Wiring Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
5-1 Machine Configuration Programming Information (Software Version P1.10). . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-2 Machine Model Adjustment (Software Version P1.10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
6-1 Personalities Menu Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-2 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-3 Calibrations Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-4 Platform 110% Calibration Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-5 Platform 100% Calibration Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-6 Platform 120% Calibration Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-7 LSS Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
7-1 Diagnostic Trouble Codes (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
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vi 3121788
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
This page left blank intentionally
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SECTION 1 - SPECIFICATIONS
3121788 1-1
SECTION 1. SPECIFICATIONS
1.1 SPECIFICATION.
Table 1-1. Operating Specifications
DESCRIPTION 3246R 2632R
PLATFORM
MaximumWorkingHeight 38ft.(11.6m) 31.5ft.(9.6m)
Platform Lift Time
No Load:
RatedLoad:
42sec
50sec
33sec
39sec
Platform Lift Down Time
No Load:
RatedLoad:
44sec
37sec
36sec
29sec
GroundClearance
PHPDeployed
PHPRetracted
BreakoverAngle(Retracted)
0.91in(23mm)
3.9in(98mm)
12°
0.91in(23mm)
3.9in(98mm)
12°
OccupiedFloorArea 30.1ft²(2.80m²) 21.0ft²(1.95m²)
ElectronicArmGuardPauseHeight(CE/GBonly) 73in(1.85m) 66in(1.68m)
E l e c t r o n i c A r m G u a r d H e i g h t L i f t D o w n T i m e ( C E / G B o n l y ) 6 s e c ( a p p r o x . ) 5 s e c ( a p p r o x . )
DRIVING
MaximumOperatingSlope(platformfullyelevated)
Front to Back:
Side to Side:
3.5°
1.5°
HighDriveSpeed(FWD/REV) 2.2mph(3.5kph) 2.0mph(3.2kph)
ElevatedDriveSpeed(FWD/REV) 0.5mph(0.8kph)
ElevatedDrivePlatformHeight 65in(1.65m) 55in(1.40m)
MaximumStowedTravelGrade(Sideslope) 8.75%(5°)
Gradeability 25%/(14°)
Turning Radius Inside:
(Curbto Curb) Outside:
(WalltoWall) Outside:
0in.(0cm)
88.5in.(2.25m)
93.3in.(2.37m)
0in.(0cm)
82.2in.(2.09m)
86.9in.(2.21m)
CHASSIS
ApproximateGrossMachineWeight
AllMarkets:
AUSOnly:
GBOnly:
5410lb.(2454kg)
5510lb.(2499kg)
5480lb.(2486Kg)
4280lb.(1941kg)
4280lb.(1941kg)
4335lb.(1966Kg)
MaximumTireLoad(perwheel) 2150lb.(975kg) 1373lb.(623kg)
GroundBearingPressure 131psi(9.03bar) 92psi(6.34bar)
Maximum Hydraulic Pressure
Main Relief:
Steer Relief:
Lift Relief:
3200psi(220.6bar)
1150psi(79.3bar)
2550psi(175.8bar)
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SECTION 1 - SPECIFICATIONS
1-2 3121788
Platform Capacities Machine Dimensional Data
Tires
Table 1-2. Platform Capacities
DESCRIPTION 3246R 2632R
OperatingPersonnel
Indoor
Outdoor
Outdoor(AUSOnly)
2persons
1person
1person
2persons
1person
*
PlatformRatedLoad
Indoor
Outdoor(AllMarkets)
Outdoor(AUSOnly)
705lb(320kg)
507lb(230kg)
705lb(320kg)
507lb(230kg)
275lb(125kg)
*
ExtensionDeckRated
Load 265lb(120kg)
MaximumOperating
WindSpeed
Indoor
Outdoor
0mph(0m/s)
28mph(12.5m/s)
MaximumHorizontal
SideForce
Indoor
Outdoor
90lb(400N)
45lb(200N)
NOTE: (*) Machine 2632R does not have outdoor
functionality in the AUS market.
NOTE: INDOOR USE is use of a MEWP in areas shielded
from wind so that there is no wind. OUTDOOR
USE is use of a MEWP in an environment that
can be exposed to wind.
Table 1-3. Dimensions
DESCRIPTION 3246R 2632R
MaximumPlatformHeight 32ft(9.75m) 25.50ft(7.77m)
OverallMachineHeight
(Stowed)
Telescope Rails
DualRails
RailsFolded
7.96ft(2.43m)
8.03ft(2.45m)
6.47ft(1.97m)
7.30ft(2.23m)
7.29ft(2.22m)
5.81ft(1.77m)
OverallMachineHeight(Ele-
vated)
Telescope Rails
DualRails
35.72ft(10.89m)
35.78ft(10.91m)
29.17ft(8.89m)
29.23ft(8.91m)
PlatformHeight(Groundto
PlatformFloor)
Stowed
Elevated
SafetyPropEngaged
4.24ft(1.29m)
32ft(9.75m)
8.50ft(2.59m)
3.63ft(1.11m)
25.50ft(7.77m)
7.15ft(2.18m)
RailHeight(PlatformFloorto
Top of Rail)
Telescope Rails
DualRails
3.72ft(1.13m)
3.78ft(1.15m)
3.66ft(1.12m)
3.66ft(1.12m)
OverallMachineWidth 3.83ft(1.17m) 2.67ft(0.81m)
OverallMachineLength 7.86ft(2.40m)
ExtensionDeckLength 3ft(0.91m) 2.83ft(0.86m)
Wheelbase 6.18ft(1.88m)
Table 1-4. Tire Specifications
DESCRIPTION 3246R 2632 R
Size 16in.x5in.
(406mmx127mm)
WheelNutTorque
(2inch(51mm)-Slot-
tedNutwithCotterPin)
150ft.lbs.(203Nm)
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SECTION 1 - SPECIFICATIONS
3121788 1-3
Batteries
NOTICE
JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE
DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED
BATTERIES.
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH
JLG’S AFTERMARKET PARTS DISTRIBUTION CENTERS OR JLG'S AFTERMAR-
KET PROGRAMS. FOR ASSISTANCE WITH PROPER BATTERY REPLACE-
MENT, PLEASE CONTACT YOUR LOCAL JLG SUPPORT OFFICE.
BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COMPATIBILITY
WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHAR-
GER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES. THE USE OF
NON-APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY RESULT IN
PERFORMANCE ISSUES OR BATTERY CHARGER FAULT CODES. JLG
ASSUMES NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES
ARISING FROM THE USE OF NON-APPROVED BATTERIES.
Motors
• Drive Motors (3246R)
Type: Hydraulic
Displacement: 280 cc/rev (17.1 in3/rev)
Max. Torque: 6460 lb-in (730 Nm) - Continuous
Max. Torque: 8218 lb-in (929 Nm) - Intermittent
Min. Starting Torque: 5479 lb-in (619 Nm) -
Continuous
Min. Starting Torque: 6967 lb-in (787 Nm) -
Intermittent
Max. Power: 45 hp (34 kW)
Max. Oil Flow: 18 gpm (68 lpm) - Continuous
Max. Oil Flow: 25 gpm (95 lpm) - Intermittent
Max. Speed: 335 rev/min at Max. Intermittent
flow
• Drive Motors (2632R)
Type: Hydraulic
Displacement: 364 cc/rev (22.2 in3/rev)
Max. Differential Pressure : 2500 psi (172 bar) -
Continuous
Max. Differential Pressure : 3500 psi (224 bar) -
Intermittent
Max. Differential Pressure : 4350 psi (300 bar) -
Peak
•HydraulicBrake
Type: Hydraulic Release
Holding Torque: 10,000 lb-in (1130 Nm)
Max. Speed: 250 rpm
Release Pressure: 406 psi (28 bar)
Max. Release Pressure: 3000 psi (207 bar)
Release Volume: 0.7 cu. in. (11.5 cc)
• Hydraulic Pump/Electric Motor (3246R)
Motor Type: 24V DC Wound Field
Motor Power: 4.5 kW
Pump Displacement: 0.226 cu in. /rev (3.7 cc/rev)
Pump Pressure: 3000 psi Peak
4000 psi Intermittent
• Hydraulic Pump/Electric Motor (2632R)
Motor Type: 24V DC Wound Field
Motor Power: 4.5 kW
Pump Displacement: 0.29 cu in. /rev (4.77 cc/rev)
Pump Pressure: 2100 psi Continuous
3500 psi Intermittent
DESCRIPTION Lead Acid Lead Acid
(Extended Range) AGM
Voltage(24VSystem) 6Vperbattery
AmpHourRating 225Ah@20HRrate 255Ah@20HRrate 213Ah
ReserveCapacity 447Minutes 570Minutes 492min
Weight(eachbattery) 63lb.(28.6kg) 75lb.(34kg) 66lb(30kg)
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SECTION 1 - SPECIFICATIONS
1-4 3121788
Electrical System
Table 1-5. Battery Charger Specifications
DESCRIPTION 2632R/3246R
ElectricalSystemVoltage(DC) 24V
BatteryCharger:
Input:
ACInputVoltage:
NominalACInputVoltage:
InputFrequency:
Max.ACInputCurrent:
IngressProtection:
OperatingTemperature:
Output:
NominalDCOutputVoltage:
Max.DCOutputVoltage:
MaxDCOutputCurrent:
Max.InterlockCurrent:
Protection:
OutputReversePolarity:
OutputShortCircuit:
ACOverload:
DCOverload:
Delta-Q
85-270VAC
100VAC/240VACRMS
50-60Hz
7.5A
IP66NEMA4Type4
-40°F(-40°C)to149°F(+65°C)
24V
36V
27.1A
1A@24V
ElectronicProtection-AutoReset
CurrentLimited
CurrentLimited
CurrentLimited
PRO-Eagle PerformanceSeries
108-132VAC
120VACRMS
45-65Hz
12A
IP35
-22°F(-30°C)to122°F(+50°C)
24V
31.92V
25A
1A@24V
ElectronicProtection-AutoReset
ElectronicProtection-AutoReset
BranchCircuitProtection
CurrentLimited
GreenPower-PylonInternational
100-240VAC
——
45-65Hz
8.5A
IP66
-4°F(-20°C)to122°F(+50°C)
24V
34V
30A
1A@24V
ElectronicProtection-AutoReset
ElectronicProtection-AutoReset
CurrentLimited
CurrentLimited
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SECTION 1 - SPECIFICATIONS
3121788 1-5
1.2 LIMIT SWITCH ACTIVATION
Tilt Alarm
NOTE: When the tilt indicator warning is activated the fol-
lowing functions are affected;
Platform Lowered: Only Drive Allowed.
Platform Raised: Drive and lift up functions are dis-
abled, platform must be fully lowered (stowed) to
drive out of tilt condition.
1.3 LUBRICATION
Capacities
Specifications
NOTE: Aside from JLG recommendations, it is not advisable
to mix oils of different brands or types, as they may
not contain the same required additives or be of
comparable viscosities.
MODEL
Tilt Setting
Y-Axis
(Front To Back)
Tilt Setting
X-Axis
(Side To Side)
Platform Height
3246R 3.5°
1.50°-outdoor
2.50°-indoor 27-32ft(8.23-9.75m)
2.25°-outdoor
2.75°-indoor 22-27ft(6.7-8.23m)
3.50°-outdoor
3.75°-indoor 5.4-22ft(1.65-6.7m)
2632R 3.5°
1.50°-outdoor
1.50°-indoor
18-21ft(5.84-6.4m)
20.5-26ft(6.2-7.9m)
2.50°-outdoor
2.25°-indoor
14-18ft(4.2m-5.4m)
16.5-20.5ft(5m-6.2m)
4.50°-outdoor
3.50°-indoor
14ft(4.2m)
16.5ft(5m)
Table 1-6. Capacities
COMPONENT 3246R 2632R
Hydraulic Reservoir
(at Full mark) 4gal(15L)
HydraulicSystem(Including
Reservoir) 5.5gal(21L) 4.75gal(18L)
Table 1-7. Specifications
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350°
F. Excellent water resistance and adhesive qualities, and being
of extreme pressure type. (Timken OK 40 pounds minimum.)
EPGL ExtremePressureGearLube(oil)meetingAPIserviceclassifica-
tionGL-5orMIL-SpecMIL-L-2105.
HO JLGRecommends-Mobil-Mobilfluid424
MobilEALENVIRONSYNH32
MobilSHCHYDRAULICEAL32
EALandSHC arecompatiblewitheachother.
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SECTION 1 - SPECIFICATIONS
1-6 3121788
1.4 HYDRAULIC OIL
Table 1-8. Mobilfluid 424 Specs
Inspection Data Recommended
Mobilfluid 424
Optional
HYKEN 052
SAE Viscosity Grade 10W-30 10W-20
Spec Gravity API 29.0 29.3
Density, LB/GAL, 60° F 7.35 7.3
FlashPoint,°F(°C) 442(228) 380(193)
PourPoint,°F(°C) -46(-43) -30(-34)
Viscosity
Brookfield,cPat-18°C 2700 --
Brookfield,cPat0°F -- 2500
Viscosity,cSTat40°C 55 52.1
Viscosity,cSTat100°C 9.3 8.95
Viscosity Index 152 152
Viscosity,SUSat100°F -- 26.0
Viscosity,SUSat210°F -- 56.8
Color,ASTMD1500 3.0 --
Table 1-9. Biodegradable Hydraulic Fluid Specs
Inspection Data
MOBIL EAL
ENVIRONSYN
H 32
MOBIL SHC
HYDRAULIC
EAL 32
ISOViscosity Grade 32 32
Density@15°C
ASTMD4052,kg/L
0.869 0.936
FlashPoint,ASTMD97
°F(°C)
514(268) 540(282)
PourPoint,ASTM D92
°F(°C)
-38(-39) -27(-33)
OperatingTemp,°F(°C) -20(-29)to200(93) 1.4(-17)to200(93)
Viscosity
Viscosity,ASTMD445
cSTat40°C
33.1 31.1
Viscosity,ASTMD445
cSTat100°C
6.36 6.2
ViscosityIndex,ASTMD
2270
147 152
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SECTION 1 - SPECIFICATIONS
3121788 1-7
Specified lubricants, as recommended by the component
manufacturers, are always the best choice, however, multi-
purpose greases usually have the qualities which meet a
variety of single purpose grease requirements.
Should any question arise, regarding the use of greases in
maintenance stock, consult your local supplier for evalua-
tion. Refer to Table 1-7, Specifications for an explanation of
the lubricant key designations.
IN THIS REGION FUNCTION SPEEDS
& BATTERY LIFE TIME MAY BE
SIGNIFICANTLY REDUCED
AIR TEMPERATURE
˚C ˚F
+49
+43
+38
+32
+27
+21
+16
+10
+4
-1
-7
-12
-18
-23
-29
-34
-40
+120
+110
+100
+90
+80
+70
+60
+50
+40
+30
+20
+10
0
-10
-20
-30
-40
MOBIFLUID 424
MOBIL EAL ENVIRONSYS H 32
MOBIL 10 EXCEL 32
MOBIL 10 EXCEL 15
*APPROVED FOR 4045R ONLY*
Mobilfluid 424
Mobil EAL Envirosyn H 32
Mobil DTE 10 Excel 32
Mobil DTE 10 Excel 15
Description
55
33
32
15
(CsT, Typical)
Viscosity @ 40˚c
Fluid
145
147
164
168
Visc Index
Mineral Oils
Vegetable Oils
Synthetic
Synthetic
Polyol Esters
Properties Base Classification
X
X
X
XX
X
X
Fire Resistant***
Non - toxic ** Virtually
Biodegrageable * Readily
MAF11160
* Readily biodegradable classification indicates one of the following:
C02 Conversion>60% per EPA 560/6 - 82- 003
C02 Conversion>80% per CEC - L - 33 - A - 93
** Virtually Non - toxic classification indicates an LC50>5000 ppm per OECD 203
*** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval
NOTICE:
MACHINE OPERATION USING NON - JLG APPROVED HYDRAULIC FLUIDS OR OPERATION
OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "HYDRAULIC FUILD
OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF
THE HYDRAULIC SYSTEM.
1001219909-D
Figure 1-1. Hydraulic Oil Operating Temperature Specifications
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SECTION 1 - SPECIFICATIONS
1-8 3121788
1.5 HYDRAULIC PRESSURE SETTINGS
1.6 HYDRAULIC CYLINDER SPECIFICATIONS
1.7 SERIAL NUMBER LOCATION
For machine identification, a serial number plate is affixed
to the machine.
1.8 CRITICAL STABILITY WEIGHTS
DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES
OR TIRES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO
NOT MODIFY THE MEWP IN ANY WAY TO AFFECT STABILITY.
MODEL MAIN RELIEF LIFT RELIEF STEER RELIEF
3246R/2632R 3200psi(220bar) 2550psi(176bar) 1150psi(80bar)
DESCRIPTION 3246R 2632R
LiftCylinderBoreDiameter 3.94in.(100mm) 3.54in.(80mm)
LiftCylinderStroke 47.85in.(1215.5mm) 47.6in.(1210.5mm)
LiftCylinderRodDiameter 2.56in.(65mm) 2.36in.(60mm)
SteerCylinderBoreDiameter 2.36in.(60mm)
SteerCylinderStroke
(total)
5.75in.(146mm) 6.2in.(160mm)
SteerCylinderRodDiameter 1.38in.(35mm)
MAF10110
Serial Number
Plate
Rear View
3246R/2632R
COMPONENT 3246R 2632R
WheelandTireAssembly(each) 52.7lb.(23.9kg)
Wheel/Tire and Drive Assembly
(each) 83lb(37.6kg) 81.1lb(36.8kg)
Wheel/Tire and Brake Assembly
(each) 90lb.(40.8kg) 89.7lb(40.7kg)
Batteries(each)
Standard:
AGM:
ExtendedRange:
63lb(28.6kg)
66lb(30kg)
75lb(34kg)
Batteries(combinedX4)
Standard:
AGM:
Extended Range:
252lb(114kg)
265lb(120kg)
300lb(136kg)
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SECTION 1 - SPECIFICATIONS
3121788 1-9
1.9 MAJOR COMPONENT WEIGHTS 1.10 TORQUE REQUIREMENTS
Self-locking fasteners, such as nylon insert and thread
deforming locknuts, are not intended to be reinstalled
after removal. Always use new replacement hardware
when installing locking fasteners.
NOTE: When maintenance becomes necessary or a fas-
tener has loosened, refer to the Torque Charts on
page 1-10 to determine proper torque value.
3246R 2632R
COMPONENT
(ANSI/CSA/
KOR/JPN/CE/
GB)
(AUS) ALL
MARKETS
PlatformwithRails/Extension
(RailinRail)
474lb.
(215Kg)
474lb.
(215Kg)
388lb.
(176Kg)
PlatformwithRails/Extension
(DualRail)
494lb.
(224Kg)
494lb.
(224Kg)
409lb.
(186Kg)
ArmAssembly-
(IncludingLiftCylinder)
1984lb.
(900Kg)
1984lb.
(900Kg)
1142lb.
(518Kg)
Chassisw/Wheels/Tires/
Steering/PHPandDrive
Assemblies
2951lb.
(1339Kg)
3051lb.
(1384Kg)
2750lb.
(1247Kg)
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SECTION 1 - SPECIFICATIONS
1-10 3121788
Torque Charts
Figure 1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
Torq ue
To rqu e Torq ue To rqu e Torq ue Torq ue
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