JLG 2632R Service Maintenance Manual
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JLG 2632R Service Maintenance Manual

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Service & Maintenance Manual
Models
2632R
3246R
3121788
April 12, 2019 - Rev B
AS/NZS GB

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Summary of Contents for JLG 2632R

  • Page 1 Service & Maintenance Manual Models 2632R 3246R 3121788 April 12, 2019 - Rev B AS/NZS GB...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 3: Sectiona - Introduction - Maintenance Safety Precautions

    • USE ONLY REPLACEMENT PARTS OR COMPONENTS the machine is safe to operate. THAT ARE APPROVED BY JLG. TO BE CONSIDERED APPROVED, REPLACEMENT PARTS OR COMPONENTS MUST BE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.
  • Page 4 SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue........... February 14, 2019 Revised............... April 12, 2019 3121788...

  • Page 5: Table Of Contents

    Hydraulic Pump And Electric Motor Assembly - 2632R ....... . .
  • Page 6 SECTION 5 - JLG CONTROL SYSTEM Hand Held Analyzer ................5-1 Joystick Calibration .
  • Page 7 3-41. Scissor Arm Assembly (2632R) - Cable Routing (Coiled) (With Foot Switch) ......3-47 4-1.
  • Page 8 Hydraulic Schematic (2632R) - Sheet 1 of 2 ....... . .
  • Page 9 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications ................1-1 Platform Capacities .

  • Page 10: Table No

    LIST OF TABLES TABLE NO. TITLE PAGE NO. This page left blank intentionally 3121788...

  • Page 11: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS SPECIFICATION. Table 1-1. Operating Specifications DESCRIPTION 3246R 2632R PLATFORM Maximum Working Height 38 ft. (11.6 m) 31.5 ft. (9.6 m) Platform Lift Time 42 sec 33 sec No Load: 50 sec 39 sec...

  • Page 12: Platform Capacities

    Outdoor 45 lb (200 N) Overall Machine Width 3.83 ft (1.17 m) 2.67ft (0.81 m) NOTE: (*) Machine 2632R does not have outdoor Overall Machine Length 7.86 ft (2.40 m) functionality in the AUS market. Extension Deck Length 3 ft (0.91 m) 2.83 ft(0.86 m)
  • Page 13 75 lb. (34 kg) 66 lb (30 kg) • Drive Motors (2632R) NOTICE Type: Hydraulic JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED Displacement: 364 cc/rev (22.2 in /rev) BATTERIES.

  • Page 14: Battery Charger Specifications

    SECTION 1 - SPECIFICATIONS Electrical System Table 1-5. Battery Charger Specifications DESCRIPTION 2632R/3246R Electrical System Voltage (DC) Battery Charger: Delta-Q PRO - Eagle Performance Series Green Power - Pylon International Input: AC Input Voltage: 85-270V AC 108-132V AC 100 -240V AC...

  • Page 15: Limit Switch Activation

    16.5 ft (5 m) EAL and SHC are compatible with each other. 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.

  • Page 16: Hydraulic Oil

    SECTION 1 - SPECIFICATIONS HYDRAULIC OIL Table 1-8. Mobilfluid 424 Specs Recommended Optional Inspection Data Mobilfluid 424 HYKEN 052 SAE Viscosity Grade 10W-30 10W-20 Spec Gravity API 29.0 29.3 Density, LB/GAL, 60° F 7.35 Flash Point, ° F (° C) 442 (228) 380 (193) Pour Point, °...
  • Page 17 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.

  • Page 18: Hydraulic Pressure Settings

    STEER RELIEF DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES 3246R/2632R 3200 psi (220 bar) 2550 psi (176 bar) 1150psi (80 bar) OR TIRES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY THE MEWP IN ANY WAY TO AFFECT STABILITY.

  • Page 19: Major Component Weights

    SECTION 1 - SPECIFICATIONS MAJOR COMPONENT WEIGHTS 1.10 TORQUE REQUIREMENTS Self-locking fasteners, such as nylon insert and thread 3246R 2632R deforming locknuts, are not intended to be reinstalled after removal. Always use new replacement hardware (ANSI/CSA/ when installing locking fasteners.
  • Page 20 SECTION 1 - SPECIFICATIONS Torque Charts Figure 1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 1-10 3121788...
  • Page 21 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 3121788 1-11...
  • Page 22 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 1-12 3121788...
  • Page 23 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 3121788 1-13...
  • Page 24 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 1-14 3121788...
  • Page 25 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 26: General

    JLG Service Training School for the subject JLG prod- environment, severity and frequency of usage requires.

  • Page 27: Inspection And Maintenance Responsibilities

    Preventative Owner, Dealer, or At intervals as specified in the Service and Maintenance Manual. Qualified JLG Mechanic Service and Maintenance Manual Maintenance User NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121788...

  • Page 28: Preventive Maintenance And Inspection Schedule

    TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE 2. Visual inspection for damage: (cracks, corrosion, JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT abrasions, distortion, excessive wear, broken welds, MODEL. gouges, chafing and threads showing).

  • Page 29: Preventive Maintenance & Inspection Schedule

    SECTION 2 - GENERAL Table 2-2. Preventive Maintenance & Inspection Schedule. INSPECTIONS AREA ON MACHINE PRE-DELIVERY ANNUAL (YEARLY) OR FREQUENT INSPECTION INSPECTION Scissor Arms Scissor arms 1, 2 1, 2 Safety prop 1, 2 1, 2 Nuts, bolts, shafts, shields, bearings and locking devices 1, 2 1, 2 Cylinder/Pivot pins and attaching hardware...
  • Page 30 No unauthorized modification or additions Paint and overall appearance. Operation and safety manual General Structural Condition and Welds Grease and lubrication specification Function test of all system Notify JLG change in machine ownership ANSI and AEM handbook Capacity Decals All decals/placards 3121788...
  • Page 31 SECTION 2 - GENERAL Table 2-2. Preventive Maintenance & Inspection Schedule. (Continued) INSPECTIONS AREA ON MACHINE PRE-DELIVERY ANNUAL (YEARLY) OR FREQUENT INSPECTION INSPECTION Annual machine inspection Safety publication All fasteners, pins, shields and covers 1, 2 1, 2 Footnotes: Prior to each sale, lease, or delivery. In service for 3 months;...

  • Page 32: Service Maintenance Components

    SECTION 2 - GENERAL 2.3 SERVICE MAINTENANCE COMPONENTS MAF10020 Figure 2-1. Machine Component Locations - 3246R 1. Scissor Arm 4. Batteries Location 2. Hydraulic Tank 5. Safety Prop 3. Pump Assembly 3121788...
  • Page 33 SECTION 2 - GENERAL MAF12790 Figure 2-2. Machine Component Locations - 2632R 1. Scissor Arm 4. Batteries Location 2. Hydraulic Tank 5. Safety Prop 3. Pump Assembly CAUTION Scissor Arm - Safety Prop SAFETY PROP MUST BE USED WHENEVER MAINTENANCE PERFORMED (See Figure 2-3.
  • Page 34 SECTION 2 - GENERAL Hydraulic Oil Check Procedure (Figure 2-5., and Figure 2-6.) • Lube Points - Hydraulic Reservoir • Reservoir Capacity - 4 gal. (15 L) • Lube - Hydraulic Oil • Interval - Check Daily To ensure proper operation of the machine, the hydrau- lic oil must be checked daily.

  • Page 35: Service And Guidelines

    SECTION 2 - GENERAL NOTE: Recommended lubrication intervals are based on 2.4 SERVICE AND GUIDELINES machine operations under normal conditions. For machines used in multi-shift operations and/or General exposed to hostile environments or conditions, The following information is provided to assist you in lubrication frequencies must be increased accord- the use and application of servicing and maintenance ingly.
  • Page 36 SECTION 2 - GENERAL Components Removal and Installation Gaskets 1. Use adjustable lifting devices, whenever possible, if Check that holes in gaskets align with openings in the mechanical assistance is required. All slings (chains, mating parts. If it becomes necessary to hand-fabricate cables, etc.) should be parallel to each other and as a gasket, use gasket material or stock of equivalent near perpendicular as possible to top of part being...

  • Page 37: Lubrication And Information

    Hydraulic Oil 1. Refer to Section 1 for recommendations for viscos- ity ranges. 2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscos- ity index of 152. NOTE: Start-up of hydraulic system with oil temperatures below -15°F (-26°C) is not recommended.

  • Page 38: Cylinder Drift Test

    SECTION 2 - GENERAL 2.6 CYLINDER DRIFT TEST 2.7 PINS AND COMPOSITE BEARING REPAIR GUIDELINES Maximum acceptable cylinder drift is to be measured using the following methods. Filament wound bearings. 1. Pinned joints should be disassembled and Platform Drift inspected if the following occurs: Measure the drift of the platform to the ground.
  • Page 39 SECTION 2 - GENERAL NOTES: 2-14 3121788...
  • Page 40 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 41: Chassis & Scissor Arms

    SECTION 3. CHASSIS & SCISSOR ARMS LEFT AND RIGHT SIDE COMPARTMENT COMPONENTS MAF10280 Figure 3-1. Components on left Side Swing - Out Compartment Door (2632R and 3246R) 1. Left Side Component Compartment Door 4. Pump Power Module 2. Compartment Latch and Release Handle 5.
  • Page 42 SECTION 3 - CHASSIS & SCISSOR ARMS MAF12610 Figure 3-3. Components on right Side Swing - Out Compartment Door (2632R) 1. Right Side Component Compartment Door 3. Hydraulic Assembly 2. Compartment Latch and Release Handle 4. Hydraulic Tank w/Filter 3121788...
  • Page 43 NOTE 1: To adjust SURFACE A to be parallel with SURFACE B within 3mm when doors are closed. Rotate the Door Adjuster Bolt in clockwise to decrease and counterclockwise to increase the distance between surface A and B. NOTE 2: Apply JLG Threadlocler PN 0100011 to Bolts before installation. 3121788...

  • Page 44: Battery Removal/Maintenance

    CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES. machine, first disconnect the positive (+) battery THE USE OF NON APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY cable from the forward most battery connected RESULT IN PERFORMANCE ISSUES OR BATTERY CHARGER FAULT to the main contactor relay.

  • Page 45: Battery Charging

    SECTION 3 - CHASSIS & SCISSOR ARMS Battery Maintenance and Safety Practices BATTERY CHARGING Non-Sealed - Refillable Lead Acid Batteries Only NOTE: Be sure that machine is parked in a well ventilated area before charging begins. CAUTION CAUTION ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT WITH SKIN OR CLOTHING.
  • Page 46 SECTION 3 - CHASSIS & SCISSOR ARMS Delta-Q - Battery Charger Green Power - Battery Charger - (China (GB) Only) MAF10320 1. AC Voltage Input Cable 2. Charge Indicator LEDs • Battery Charging: Yellow LED - AGM - flashes quickly; Flooded - remains on / AGM flooded - flashes slowly MAF10300 •...
  • Page 47 3. If the output voltage of the charger seems exces- Battery Charger Maintenance sive, return the charger for service. Contact JLG to get the expected battery voltage settings for CAUTION the charger in question. Be sure to have the char- ger’s serial number and charge algorithm setting...
  • Page 48 SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-1. Diagnostic Trouble Codes (Delta Q Battery Charger) Fault Solution Check the battery voltage and cable connections. Check battery size and condition. E-0-0-1 Battery high voltage E-0-2-1 This error will automatically clear once the condition has been corrected. Check the battery voltage and cable connections.

  • Page 49: Fault Codes (Green Power)

    SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-2. Fault Codes (Green Power) Flash Code Cause Solution 1) Check battery connection is correct. Connection Issue 2) Check charger connection is correct. 3) Check each battery is good. 1) Check AC input cord is connected between charger and AC outlet. Abnormal AC Power Input (Voltage) 2) Make sure AC plug is tightly secured into AC outlet.

  • Page 50: Fault Codes (Eagle Battery Charger)

    SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-3. Fault Codes (Eagle Battery Charger) LED Indications Fault Solution This indication occurs whenever the charger circuitry cannot detect a bat- tery. The charger circuitry will not allow charge current to flow under this 30% RED LED NO BATTERY DETECTED condition.

  • Page 51: Dc/Ac Power Inverter Installation - Option

    SECTION 3 - CHASSIS & SCISSOR ARMS DC/AC POWER INVERTER INSTALLATION - OPTION Set the master power switch (item 5) on the side of the inverter unit to ON and leave it there. Use the inverter on/ DESCRIPTION ALL MACHINES off switch at the Ground Control panel (see Ground Con- Electrical System Voltage (DC) trol Station - page 3-16, item 3) to power the inverter on...

  • Page 52: Logic Control Module Installation

    SECTION 3 - CHASSIS & SCISSOR ARMS LOGIC CONTROL MODULE INSTALLATION All machine electrical functions are controlled through the logic control module, the logic control module also moni- tors all the machine’s electrical systems. If a system fault should happen with the logic module or one of the machine’s electrical systems, the logic module will gener- ate a DTC code.

  • Page 53: Main Power Contactor Relay And Pump Control Module

    SECTION 3 - CHASSIS & SCISSOR ARMS MAIN POWER CONTACTOR RELAY AND PUMP NOTICE CONTROL MODULE DISCONNECT MAIN POWER FROM THE BATTERIES BEFORE ATTEMPT- ING TO REMOVE THE MAIN POWER CONTACTOR RELAY OR SERVICING The main power contactor relay and pump control mod- THE ELECTRICAL SYSTEM.

  • Page 54: Pump Control Module

    SECTION 3 - CHASSIS & SCISSOR ARMS PUMP CONTROL MODULE Table 3-5. Pump Power Module Terminal Functions (CO117-J1) The pump control module (item 7 - “Main Power Con- J1-1 Power Input (8 - 40 V) - Input tactor Relay and pump control Module” on page 3-13) is located inside the left side component door, mounted J1-2 Speed Command Input(0-5 V) - Input...
  • Page 55 SECTION 3 - CHASSIS & SCISSOR ARMS MAF10170 Figure 3-10. Hydraulic Pump Control - Power Connections 1. Batteries 6. To Logic Control Module 2. Main Power Contactor Relay 7. To Battery Charger (+) 3. Pump Control Module 8. To Battery Charger (–) 4.

  • Page 56: Ground Control Station

    SECTION 3 - CHASSIS & SCISSOR ARMS GROUND CONTROL STATION Components Location MAF10180 1. Ground/Platform/OFF Key Selector Switch 5. Hourmeter Gauge 2. Platform Lift/Lower Switch 6. Overload Indicator 7. MDI - Indicator (If Equipped) 3. Inverter ON/OFF Switch (If Equipped) 4.
  • Page 57 SECTION 3 - CHASSIS & SCISSOR ARMS MAF10190 Figure 3-11. Ground Control Station Removal 1. Ground Control Housing 6. Emergency Stop Switch 2. Attach Bolt, Washer and Tinnerman Nut 7. Hourmeter 3. Rear Panel Protective Cover 8. Overload Indicator 4. Platform/OFF/Ground Select Switch 9.

  • Page 58: Platform Control Station

    NOTICE POWER MACHINE DOWN AT THE GROUND CONTROL STATION BEFORE DISCONNECTING THE PLATFORM CONTROL STATION. Overview of Control Station Components Figure 3-14. Platform Control Station Components (2632R) - External 1. Emergency Stop Switch 9. Horn Button 2. Lift/Drive Select Switch 10.
  • Page 59 SECTION 3 - CHASSIS & SCISSOR ARMS Installation/Removal Control Station Disassembly 1. Disconnect the platform control station harness 1. Place the platform control station assembly on a at the round connector on front the control sta- suitable work bench. tion. 2.
  • Page 60 SECTION 3 - CHASSIS & SCISSOR ARMS MAF10210 Figure 3-17. Platform Control Station Components (3246R) - Figure 3-18. Platform Control Station Components (2632R) - Internal Internal 1. Drive, Lift and Steer Joystick 6. Horn Button Switch 1. Drive, Lift and Steer Joystick 5.

  • Page 61: Joystick Specifications

    SECTION 3 - CHASSIS & SCISSOR ARMS Joystick Controller MAF11220 Figure 3-19. Joystick Table 3-6. Joystick Specifications Table 3-7. Connector Chart Input Voltage +5 (±0.1) VDC CONNECTOR PINOUT Current Consumption 10 mA @ 12 VDC Term Color Function HANDLE COM Output: Handle Centered 2.5 (±0.1) VDC VIOLET...

  • Page 62: Tilt Sensor Installation

    6. Reconnect the battery power to the machine. 7. Start the machine and check tilt sensor calibra- tion with handheld analyzer. See Section 5, JLG Control System for tilt sensor calibration proce- dure. Table 3-8. Tilt Sensor Wiring Pin Assignment...

  • Page 63: Arm Angle Sensor

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.11 ARM ANGLE SENSOR On LSS equipped machines this sensor works in tandem with the lift cylinder pressure switch to accurately deter- This machine is equipped with a scissor arm rotary angle mine platform load for any given platform height. sensor switch.
  • Page 64 SECTION 3 - CHASSIS & SCISSOR ARMS Arm Angle Sensor Installation 4. With the Angle sensor and bracket oriented as shown in Figure 1, carefully slide keeper pin into (See Figure 3-21.) sensor pin from other end. Secure keeper pin with mounting hardware.
  • Page 65 SECTION 3 - CHASSIS & SCISSOR ARMS MAF10350 3121788 3-25...

  • Page 66: Pot-Hole Protection System Components

    17. Bearing 18. Bolt 19. Limit Switch Mounting Screw *Torque to 11.67-14.75 ft lbs.(16-20 Nm) Apply JLG Threadlocker PN 0100011 to bolt before installation **Torque not more than 2.58 ft lbs. (3.5 Nm) MAF10400 Figure 3-22. Pot-Hole Protection Assembly (3246R)
  • Page 67 17. Bearing 18. Bolt 19. Limit Switch Mounting Screw *Torque to 11.67-14.75 ft lbs.(16-20 Nm) Apply JLG Threadlocker PN 0100011 to bolt before installation **Torque not more than 2.58 ft lbs. (3.5 Nm) 1001237737-D MAF12640D Figure 3-23. Pot-Hole Protection Assembly (2632R)
  • Page 68 SECTION 3 - CHASSIS & SCISSOR ARMS NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS, BLOCKING, OR OVERHEAD SLING. 1. Install flange bearings into the frame holes with the flange side facing inside of frame against Pot- Hole bar hinge.

  • Page 69: Steer And Spindle Assembly Components

    Figure 3-24. Steer and Spindle Assembly Installation (3246R) 1. Mount steer cylinder with ports facing the rear of the machine. 3. Spindle weldment interchangeable with either side. 2. Apply JLG Thread locker PN 0100011 to bolt threads before 4. Steering Lug tightening.
  • Page 70 Figure 3-25. Steer and Spindle Assembly Installation (2632R) 1. Mount steer cylinder with ports facing the rear of the machine. 3. Spindle weldment interchangeable with either side. 2. Apply JLG Thread locker PN 0100011 to bolt threads before 4. Steering Lug tightening.
  • Page 71 SECTION 3 - CHASSIS & SCISSOR ARMS Drive Motor Covers Installation - Option MAF10260 Figure 3-26. Drive Motor Cover Installation - Option NOTE: Cover installation same for both sides. 1. Drive Motor Cover 2. Cover carriage bolts, nuts, and washers 3121788 3-31...
  • Page 72 JLG as an approved replacement. Please refer to 4. Install cotter pin (2), if hole in slots do not align the JLG Parts Manual for the part number of the approved with cotter pin hole on the tapered shaft, con- tires for a particular machine model.

  • Page 73: Arms And Platform Positioning And Support

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.14 ARMS AND PLATFORM POSITIONING AND 3.16 SCISSOR ARMS REMOVAL SUPPORT 1. Remove platform (refer to Section 3.15, Platform Removal). 2. Disconnect all wiring and cables attached to scissor arm assembly. NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS, BLOCKING OR 3.
  • Page 74 SECTION 3 - CHASSIS & SCISSOR ARMS MAF10270 Figure 3-28. Arms and Platform Positioning with Overhead Support 3-34 3121788...
  • Page 75 SECTION 3 - CHASSIS & SCISSOR ARMS MAF10410 Figure 3-29. Platform Assembly - Installation/Removal 3121788 3-35...
  • Page 76 SECTION 3 - CHASSIS & SCISSOR ARMS MAF10090 Figure 3-30. Scissor Arm Assembly (3246R) 3-36 3121788...
  • Page 77 SECTION 3 - CHASSIS & SCISSOR ARMS MAF10100 Figure 3-31. Scissor Arm Assembly - Pin Configuration (3246R) 3121788 3-37...
  • Page 78 SECTION 3 - CHASSIS & SCISSOR ARMS 1001370010-D MAF12650D Figure 3-32. Scissor Arm Assembly (2632R) 3-38 3121788...
  • Page 79 SECTION 3 - CHASSIS & SCISSOR ARMS 1001370010-D MAF12660D Figure 3-33. Scissor Arm Assembly - Pin Configuration (2632R) 3121788 3-39...
  • Page 80 SECTION 3 - CHASSIS & SCISSOR ARMS CREATE LOOP OF EXCESS CABLE AND SECURE TO PLATE CUTOUT SECURE AC CABLE ROUTE ALONG INSIDE TO ARMS USING TIE OF CABLE AS SHOWN WRAPS AT EACH WELD NUT ALONG CABLE CABLE GUIDE THE ROUTING PATH ON THE INBOARD WELDMENT...
  • Page 81 SECTION 3 - CHASSIS & SCISSOR ARMS INCORRECT WELD NUT SECURE CABLE TO PLATE CUTOUT IF NECESSARY CORRECT SECURE AC CABLE TO ARMS USING TIE WRAPS AT EACH ROUTE ALONG INSIDE WELD NUT ALONG OF CABLE AS SHOWN THE ROUTING PATH ON THE INBOARD CABLE CABLE...
  • Page 82 SECTION 3 - CHASSIS & SCISSOR ARMS INCORRECT WELD NUT CORRECT CREATE LOOP OF EXCESS CABLE AND SECURE TO PLATE CUTOUT SECURE AC CABLE TO ARMS USING TIE WRAPS AT EACH WELD NUT ALONG ROUTE ALONG INSIDE THE ROUTING PATH OF CABLE AS SHOWN TO THE INBOARD WELDMENT...
  • Page 83 SECTION 3 - CHASSIS & SCISSOR ARMS INCORRECT WELD NUT SECURE CABLE TO PLATE IF NECESSARY CORRECT SECURE AC CABLE TO ARMS USING TIE WRAPS AT EACH ROUTE ALONG INSIDE WELD NUT ALONG OF CABLE AS SHOWN THE ROUTING PATH TO THE INBOARD CABLE CABLE...
  • Page 84 ROUTE CABLE AROUND CROSS TUBE OF ARM STACK. DO NOT LEAVE EXCESS SLACK OR LOOP IN THIS AREA. SECURE PLATFORM CABLE WITH TIE STARP THROUGH CHA- SIS CUTOUT 1001239675-B MAF12690B Figure 3-38. Scissor Arm Assembly (2632R) - Cable Routing 3-44 3121788...
  • Page 85 ROUTE CABLE AROUND CROSS TUBE OF ARM STACK. DO NOT LEAVE EXCESS SLACK OR LOOP IN THIS AREA. SECURE PLATFORM CABLE WITH TIE STARP THROUGH 1001239676-B CHASIS CUTOUT MAF12570B Figure 3-39. Scissor Arm Assembly (2632R) - Cable Routing (Coiled) 3121788 3-45...
  • Page 86 AROUND CROSS TUBE OF ARM STACK. DO NOT LEAVE EXCESS SLACK OR LOOP IN THIS AREA. SECURE PLATFORM CABLE WITH TIE STARP THROUGH CHASIS CUTOUT 1001239677-B MAF12580B Figure 3-40. Scissor Arm Assembly (2632R)- Cable Routing (With Foot Switch) 3-46 3121788...
  • Page 87 CROSS TUBE OF ARM STACK. DO NOT LEAVE EXCESS SLACK OR LOOP IN THIS AREA. SECURE PLATFORM CABLE WITH TIE 1001239678-B STARP THROUGH CHASIS CUTOUT MAF12590B Figure 3-41. Scissor Arm Assembly (2632R) - Cable Routing (Coiled) (With Foot Switch) 3121788 3-47...
  • Page 88 SECTION 3 - CHASSIS & SCISSOR ARMS NOTES: 3-48 3121788...
  • Page 89 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 90: Basic Hydraulic Information & Schematics

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS SECTION 4. BASIC HYDRAULIC INFORMATION & SCHEMATICS CYLINDERS - THEORY OF OPERATION Relief Valves Cylinders are of the double acting type. The Lift and Steer Main relief valves are installed at various points within the systems incorporate double acting cylinders.

  • Page 91: Pump/Motor

    (Lift Up from Ground Mode). Troubleshooting The following difficulties can be examined using the JLG Analyzer, a voltmeter, and simple hand tools. Unless other- wise noted, the Control System shall be energized in Ground Mode during testing.
  • Page 92 After examination, re-connect the Pump Pump Motor will not operate. Under DIAGNOS- Motor Positive Terminal and main power at the TICS - PUMP, the JLG Analyzer will show PUMP batteries. PWM 100% and PUMP CUR 0.0A when Lift Up is operated from Ground Mode.

  • Page 93: Hydraulic Tank Installation

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS HYDRAULIC TANK INSTALLATION 1. Machine Right Side Swing-Out Compartment Door 2. Hydraulic Oil Tank 3. Filter/Return/Breather Housing Assembly 4. Filter/Return Housing Cap 5. Cap O-Ring 6. Hydraulic Oil Filter 7. Bowl O-Ring 8.

  • Page 94: Hydraulic Pump And Electric Motor Assembly - 3246R

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS HYDRAULIC PUMP AND ELECTRIC MOTOR 4. Label and disconnect the positive (+) and nega- tive (–) power cables on the electric motor. ASSEMBLY - 3246R 5. Remove the four bolts (2), and washers from the pump/motor assembly and raise the pump end The hydraulic pump and motor are located on the right up above the oil level in the hydraulic tank.

  • Page 95: Hydraulic Pump And Electric Motor Assembly - 2632R

    HYDRAULIC PUMP AND ELECTRIC MOTOR 4. Remove the bolts and washers from the pump/ motor assembly and raise the pump end up ASSEMBLY - 2632R above the oil level in the hydraulic tank. 5. Loosen and remove the pump pressure side fit- The hydraulic pump and motor are located on the right ting and hose.
  • Page 96 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Pump/Motor Disassembly 2. Replace the pump to motor gasket and slide the pump assembly into the motor assembly align- 1. Remove the bolts and washers securing the ing the pump shaft with the motor receptacle. pump to the pump motor.
  • Page 97 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS MAF12700 Figure 4-4. Hydraulic Pump (2632R) - Motor Components 6. Pump To Motor Bolts and Washers 1. Hydraulic Pump 2. Electric Motor 7. Pump Suction Port 3. Pump Drive Shaft Seal 8. Pump Pressure Port 4.

  • Page 98: Hydraulic Manifold Valve Installation

    (Located mid-chassis inside right side compartment door) 1. Chassis Mounting Plate 3. Manifold Valve Assembly 4. Valve Mounting Washers 2. Valve Mounting Screws - (Apply JLG Threadlocker PN 0100011 and Torque to 10 ft. lb. (13.5 Nm) max.) SAE 8 SAE 8...
  • Page 99 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 170 0/+10 BAR 220 0/+10 BAR @17 LPM 50 bar 50 bar MAF12620 Figure 4-7. Hydraulic Manifold Assembly - Schematic (1001248679) 4-10 3121788...
  • Page 100 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS FRONT VIEW LEFT REAR VIEW RIGHT FRONT VIEW MAF10630 Figure 4-8. Hydraulic Manifold Assembly - Component Location 1. Lift Cylinder Control Valve Block 7. Brake Circuit Port 13. Drive Pressure Relief Adjust (Port B) 2.
  • Page 101 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS LEFT REAR VIEW RIGHT FRONT VIEW MAF10640 Figure 4-9. Hydraulic Manifold Assembly - Component Torque 1. Socket Head Screws - 16 ft. lb. (21 Nm) 7. Port B Fitting - Steer - 23 ft. lb. (31 Nm) 13.
  • Page 102 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS MAF10700 Figure 4-10. Hydraulic Hose Routing (3246R) 1. Manifold Valve Block 4. Drive Motors (Interchangeable) 7. Lift Cylinder - 5. Steer Cylinder (Also reference Figure 3-34. to Figure 3-37.) 2. Oil Tank/Filter/Drain Plug 3.
  • Page 103 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS MAF12820 Figure 4-11. Hydraulic Hose Routing (2632R) 1. Manifold Valve Block 4. Drive Motors (Interchangeable) 7. Lift Cylinder - 2. Oil Tank/Filter/Drain Plug 5. Steer Cylinder (Also reference (Figure 3-38. to 3. Pump/Motor 6.

  • Page 104: Drive Motor Installation

    4. Washers 2. Steer/Spindle Mount 5. Motor Mounting Nuts 3. Motor Mounting Screws (Apply JLG Threadlocker PN 0100011 on assembly) Torque to 74 ft. lb. (100 Nm) NOTE: The drive motors may make an audible noise when driving and turning the machine. This condition is normal due to the hydraulic oil flow characteristics of the series drive circuit.

  • Page 105: Hydraulic Brake Installation

    Figure 4-13. Hydraulic Brake - Installation 1. Hydraulic Brake Assembly (Mount with Ports on Top) 3. Washers (Inside of Frame) 2. Mounting Screws (Apply JLG Threadlocker PN 0100011 on assembly 4. Mounting Nuts and Torque to 74 ft. lb. (100 Nm)) 5.

  • Page 106: Towing

    (276 bar) at the MP port of the main control valve. (Refer to Figure 4-8.) NOTE: Refer to Section 5 for more information on using the JLG handheld analyzer and switching between access levels. Main Relief 1. Attach the Analyzer at the ground controls. Turn on the machine.

  • Page 107: Cylinder Checking Procedure

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 6. Press the up arrow key to change the Lift Up in a suitable container. After the initial discharge, default personality to 100%. Press ENTER. Then there should be no further drainage from the press ESC to return to the main menu.

  • Page 108: Lift Cylinder Removal Installation

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.13 LIFT CYLINDER REMOVAL INSTALLATION Lift Cylinder - LSS Pressure Sensor Location NOTE: If there is a pump failure, a crane or a forktruck can Lift cylinders on machines with the Load Sensing System be used to raise the platform.
  • Page 109 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1001244417-C 1001244416-B MAF10791 Figure 4-16. Lift Cylinder 1. Barrel 7. Ring, Back-up 13. Seal, Piston 19. Orifice 2. Rod 8. Bearing 14. Ring, Wear 20. Cartridge Valve 3. Head 9. O-Ring 15. O-Ring 21.
  • Page 110 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1001233449-C MAF10780C Figure 4-17. Steer Cylinder (3246R) 1. Lock 6. Ring 11. O-Ring 16. Seal 2. Barrel 7. Spacer 12. O-Ring 17. Seal, Stop 3. Rod 8. Bearing 13. O-Ring 18. Wiper 4.
  • Page 111 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1001179447-A MAF12630A Figure 4-18. Steer Cylinder (2632R) 1. Barrel 5. Rod Seal 9. Piston Seal 6. Wear Ring 10. Spacer 2. Rod 3. Head 7. O-Ring 11. Flange Bearing 4. Wiper 8. Backup Ring 12.

  • Page 112: Cylinder Repair

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.14 CYLINDER REPAIR 6. Using the proper wrench, loosen the cylinder head and remove head from cylinder barrel. NOTE: The following are general procedures that apply to When removing cylinder head do not force if the cylinders on this machine.
  • Page 113 Assembly ing. Replace as necessary. NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual for these machine models. Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 114 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove. Figure 4-24. Wiper Seal Installation 3. Place a new o-ring and back-up seal in the appli- cable outside diameter groove of the cylinder head.
  • Page 115 Piston Asssembly 10. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor cap- screws) through the drilled holes in the bushing Cylinder Rod and into the tapped holes in the piston.
  • Page 116 22. Push the piston onto the rod until it abuts the spacer end and install the attaching nut. WHEN REBUILDING THE CYLINDERS, APPLY JLG THREADLOCKER PN 0100071 TO THE PISTON NUT, THEN TORQUE PISTON NUT. REFER TO APPLICABLE CYLINDER ILLUSTRATION FOR TORQUE REQUIREMENT.

  • Page 117: Hydraulic Schematics

    SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS 4.15 HYDRAULIC SCHEMATICS Figure 4-27. Hydraulic Schematic (3246R) - Sheet 1 of 2 4-28 3121788...
  • Page 118 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS Figure 4-28. Hydraulic Schematic (3246R) - Sheet 2 of 2 3121788 4-29...
  • Page 119 STEERRIGHT RETURNLINEFILTER 10MICRON 4.77 cm³/rev 3 bar 43 psi STEER MACHINE ELEC.SCHEM. FUNCTION DESC. LIFTDOWN HV65 HV02 LIFTUP STEERLEFT HV03 HV04 STEERRIGHT HV05 DRIVEFWD HV06 DRIVEREV SHEET 1 Figure 4-29. Hydraulic Schematic (2632R) - Sheet 1 of 2 4-30 3121788...
  • Page 120 207bar 207bar 2500 psi 3000 psi 3000 psi 220 bar 1 mm 3200 psi 0.040" LIFTUP DRIVE DRIVE REVERSE FORWARD HANDPUMP ENTRYPLATE DRIVE LIFT SHEET 2 1001234721-B MAF12670B Figure 4-30. Hydraulic Schematic (2632R) - Sheet 2 of 2 3121788 4-31...
  • Page 121 SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS NOTES: 4-32 3121788...
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  • Page 123: Jlg Control System

    SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM HAND HELD ANALYZER m en u: Analyzer Display HELP: PRESS ENTER Enter Key Escape Key Stores and selects Top Level, Sub Level, To return home or access previ- and item menus ous menu Left &...
  • Page 124 SECTION 5 - JLG CONTROL SYSTEM EVERYTHING OK, Using the Analyzer: With the machine power on and the analyzer connected In ground mode, properly, the analyzer will display the following: HELP: (002) GROUND MODE OK If ENTER is pressed again, the display moves to the follow-...
  • Page 125 SECTION 5 - JLG CONTROL SYSTEM Changing the Access Level of the Hand Held Analyzer: When the analyzer is first connected, you will be in access level 2 which enables you to only view most configuration MENU: ACCESS LEVEL 1 settings which cannot be changed until you enter a pass- word to advance to a lower level.
  • Page 126 SECTION 5 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Machine Setup Analyzer When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: Once you have gained access to level 1, and a personality...

  • Page 127: Joystick Calibration

    SECTION 5 - JLG CONTROL SYSTEM JOYSTICK CALIBRATION TILT SENSOR CALIBRATION The joystick calibration should be completed if the joystick Be sure that the machine is parked and stowed on level is replaced. To perform the joystick calibration both emer- ground.

  • Page 128: Rotary Angle Sensor Calibration

    Updating the power control module software requires a the machine. laptop computer, connecting cable, and software update cd. Contact JLG Industries to acquire the software. ROTARY ANGLE SENSOR CALIBRATION Before updating the software, use the Hand-held Analyzer to view the machine’s settings (MACHINE SETUP and PER- NOTICE SONALITIES) (refer to Figure 5-3.
  • Page 129 SECTION 5 - JLG CONTROL SYSTEM 1001206398-M MAF10030M 3121788...
  • Page 130 SECTION 5 - JLG CONTROL SYSTEM 1001206398-M MAF10040M 3121788...
  • Page 131 SECTION 5 - JLG CONTROL SYSTEM 1001206398-M MAF10050M 3121788...

  • Page 132: Machine Configuration Programming Information

    SECTION 5 - JLG CONTROL SYSTEM MACHINE CONFIGURATION PROGRAMMING INFORMATION NOTE: 1. When configuring a R scissors machine, the Machine Configuration must be completed before any Personality settings can be changed, see Table 5-2. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default.

  • Page 133: Machine Model Adjustment (Personality Settings)

    SECTION 5 - JLG CONTROL SYSTEM MACHINE MODEL ADJUSTMENT (PERSONALITY SETTINGS) Table 5-2. Machine Model Adjustment (Software Version P1.10) Adjustment Adjustment Range 2632R 3246R DRIVE ACCEL 0.1 - 5.0 (Sec) DECEL 0.1 - 2.0 (Sec) MINIMUM 1 - 25% MAXIMUM 26 -100% ELEV.
  • Page 134 SECTION 5 - JLG CONTROL SYSTEM NOTES: 5-12 3121788...
  • Page 135 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 136: Lss (Load Sensing System) Service

    LOAD ' ACC'Y setting 0%. The procedure allows the control system to replace must be to the values recommended by JLG. Follow the the calculated calibration information with measured documentation furnished with factory-provided acces-...
  • Page 137 SECTION 6 - LSS (LOAD SENSING SYSTEM) SERVICE MAF11230 1. Arm Angle Sensor 3. Pressure Sensor (Rod) 2. Pressure Sensor (Barrel) Figure 6-1. LSS Component Locations 3121788...

  • Page 138: Analyzer Information

    SECTION 6 - LSS (LOAD SENSING SYSTEM) SERVICE ANALYZER INFORMATION Diagnostic Menu The Diagnostic Load menu's are another troubleshoot- Personalities Menu ing tool for the Load Sensing System. Sensor and status information is presented in real-time for the technician. The following parameter in the PERSONALITIES, LOAD menu adjust performance of the LSS.
  • Page 139 SECTION 6 - LSS (LOAD SENSING SYSTEM) SERVICE Table 6-2. Diagnostic Menu Descriptions (Continued) PARAMETER PARAMETER VALUE DIAGNOSTICS MENU (Displayed on Analyzer (Displayed on Analyzer DESCRIPTION (Displayed on Analyzer 1 Line) Line) Line) PRES2: Displays the lift cylinder head pressure 2 scaled read- 0.0-9999.9 PSI XXXX PSI ing in PSI...

  • Page 140: Calibration Preparation

    • WIND SPEED IS LESS THAN OR EQUAL TO 20 MPH attached (Electrician's Tree, Panel Carrier, etc.). (32 KPH). 10. Connect the JLG Analyzer to the diagnostic port in • CALIBRATION WEIGHT IN THE PLATFORM IS CEN- the wire harness and enter the Access Level 1 pass- TERED AND EVENLY DISTRIBUTED.

  • Page 141: Calibration And Verification Procedure

    3246R 557.7 lb. (253 Kg) 5. If successful, the Analyzer will display the COMPLETE 2632R prompt. If unsuccessful, a message will be displayed that will help lead to a resolution (reference the Trou- 2. Initiate calibration using the CALIBRATIONS ' LOAD bleshooting section of this manual).

  • Page 142: Testing

    Refer to the troubleshooting section of this manual if lines. the Load Sensing System fails to meet these guidelines. 1. Connect the JLG Analyzer to the diagnostic port in 1. Ensure the platform is empty. the wire harness and enter the Access Level 1 pass- 2.

  • Page 143: Lss Connector Pin Assignments

    1M of maximum platform height, the Ground Overload Indicator should flash, and the alarm should sound. 8. Use the JLG Analyzer to set MACHINE SETUP ' LOAD to CUTOUT PLTM. This will prevent LSS interlocks to work from Ground Mode.

  • Page 144: Lss Troubleshooting

    LSS Visual and Audible Overload Warnings fail • LSS is not enabled in the control system. Connect the JLG Analyzer and enter the Access Level 1 password (33271). Navigate to MACHINE SETUP  LOAD and adjust the configuration to CUTOUT ALL to prevent platform and ground to sound when the platform is loaded beyond rated load.
  • Page 145 RANGE LOW (8524) Only applicable if {MACHINE SETUP-> LOAD = CUTOUT ALL or CUTOUT PLTM}AND {MACHINE SETUP --> LOAD CFG = PRESSURE} and {MACHINE SETUP --> MODEL = 1532R, 1932R, 2632R, or 3247R} LIFT CYLINDER HEAD PRESSURE 2 – OUT OF For the 3246R, this fault is triggered when the upper lift cylinder head pressure reading is high.
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  • Page 147: Diagnostic Trouble Codes

    The more detailed three digit code numbers in the DTC first two digits. The machine is powered by four 6 Volt bat- column of the following tables are only indicated on a JLG teries in series, providing a nominal 24 Volts to the control handheld diagnostic analyzer.

  • Page 148: Dtc Check Tables

    SECTION 7 - DIAGNOSTIC TROUBLE CODES DTC CHECK TABLES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 001 EVERYTHING OK None None • No Motion restrictions Platform Mode and no Faults are active. 002 GROUND MODE OK None None •...
  • Page 149 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 009 DRIVE PREVENTED – ELEVATED None None • Drive State = PREVENTED The Drive Cutout functionality is enabled, and the ABOVE DRIVE CUTOUT HEIGHT Platform is Elevated above the Calibrated Cutout Height.
  • Page 150 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 2232 FUNCTION PROBLEM – DRIVE & None • MoveState = LIFT In PlatformMode, the Drive - Lift Selector Switch LIFT BOTH OPEN •...
  • Page 151 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 231 FUNCTION PROBLEM – LIFT None In Ground Mode then Lift Switch (Up or Down) in the Ground Control PERMANENTLY SELECTED •...
  • Page 152 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 23203 POT HOLE PREVENTION SWITCH • Pot-Hole State = BLOCKED The Ground Module detects a redundancy dis- 2 - INVALID SIGNAL agreement on the PHP_SW2 input for 500ms.
  • Page 153 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 2512 ELEV ANGLE SENSOR NOT None • LiftUpState = PREVENTED The input voltage from the Elevation Angle Sen- DETECTING CHANGE • PlatformHeightValue assumed sor that measures lower arm motion did not to be Full Elevation increment/decrement properly while the vehicle...
  • Page 154 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 253 DRIVE PREVENTED – CHARGER None • DriveState = PREVENTED Driving is not possible since the vehicle is charg- CONNECTED ing. •...
  • Page 155 The user changed the Model Selection using the LICS SUSPENDED – CYCLE EMS • Lift Up State = PREVENTED JLG Analyzer. All functions are being prevented • Lift Down State = PREVENTED until the EMS is cycled. • This fault shall be suppressed if DTC 9924 is active.
  • Page 156 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 321 LINE CONTACTOR WELDED OR None • Drive State = PREVENTED The Line contactor is off, but the Power Module is MISWIRED •...

  • Page 157: Diagnostic Trouble Codes (Dtc)

    SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 3311 GROUND ALARM– SHORT TO None • Disable Output Only applicable if {MACHINE SETUP->WHITE BATTERY NOISE ALARM=YES} Short to Battery was detected on WN_ALARM 332 BRAKE - OPEN CIRCUIT None •...
  • Page 158 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 33406 LIFT UP VALVE – SHORT TO None • Disable Output Short to Ground was detected on LIFT_UP_VLV GROUND • Lift Up State = PREVENTED Short to Ground was detected on LIFT_DN_VLV 33407 LIFT DOWN VALVE –...
  • Page 159 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 33676 PLATFORM POWER – SHORT TO None • PlatformMode Prevented Short to Ground was detected on GROUND • Disable output PLATFORM_PWR Ignore this Fault in GroundMode 3368 TWO SPEED VALVE - SHORT TO None...
  • Page 160 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 4235 POWER MODULE TOO HOT - None • DriveState =CREEP Curtis Code 22: Controller Overtemp Cut- REDUCED OPERATION • LiftUpState = CREEP back Set: Heatsink temperature exceeded 185°F (85°C).
  • Page 161 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 442 BATTERY VOLTAGE TOO HIGH – None • Enter SafeMode The Ground Module measured excessively high SYSTEM SHUTDOWN • LiftDownState = MAX battery voltage (VBAT) (>32.0V) and de-ener- gized the Main Line Contactor and Battery Relay to protect system devices and was unable to...
  • Page 162 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 447 VOLTAGE REFERENCE OUT OF None • DriveState = PREVENTED The Ground Modules 5V supply voltage was RANGE • LiftUpState = PREVENTED measured to be out of range (<4.5V or >5.5V).
  • Page 163 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 4476 BATTERY VOLTAGE TOO HIGH – None • Enter SafeMode The Ground Module momentarily measured UNPLUG CHARGER • LiftDownState = MAX excessively high battery voltage (VBAT) (>32.0V) and entered SafeMode to protect sys- tem devices.
  • Page 164 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 661 CANBUS FAILURE – POWER None • DriveState = PREVENTED The control system failed to receive messages MODULE • LiftUpState = PREVENTED from the Pump Module.
  • Page 165 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 8212 LSS PRESSURE SENSOR DIS- None • LiftUpState = PREVENTED if Pressure Sensor 1 (Pressure1Value) and Pressure AGREEMENT PlatfromHeightValue ? LSSMin- Sensor 2 (Pressure2Value) do not agree.
  • Page 166 {MACHINE SETUP --> MODEL is 1532R, 1932R, 2632R, or 3247R} 8527 LIFT CYLINDER HEAD PRESSURE None • OverloadState= TRUE • {MACHINE SETUP --> MODEL is 2632R, or - DISAGREEMENT 3246R} • {MACHINE SETUP-> LOAD = CUTOUT PLTM or CUTOUT ALL} •...
  • Page 167 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 8532 LIFT CYLINDER ROD PRESSURE - None • OverloadState= TRUE • Pressure3RawValue is greater than 50PSI for DISAGREEMENT 10,000mS (both ConstantData) while all of the following are true: •...
  • Page 168 The Ground Module has not been configured for MACHINE NOT CONFIGURED • LiftUpState = PREVENTED the first time. Use the JLG Analyzer to adjust all • LiftDownState = PREVENTED Machine Setup and Personality settings and re- cycle power to clear difficulty.
  • Page 169 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 9952 POWER MODULE FAILURE – None • DriveState = PREVENTED Curtis Code 43: Pump Throttle Wiper High INTERNAL ERROR • LiftUpState = PREVENTED Set: Pot2 wiper voltage is lower than the high fault threshold (can be changed with the VCL fun- citon Setup_Pot_Faults())
  • Page 170 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 9957 POWER MODULE FAILURE – None • DriveState = PREVENTED Curtis Code 68: VCL Run Time Error INTERNAL ERROR • LiftUpState = PREVENTED Set: Runtime VCL code error condition Effect: ShutdownMotor,ShutdownMainContac- tor,ShutdownEMBrake, ShutdownThrottle, Shut-...
  • Page 171 SECTION 7 - DIAGNOSTIC TROUBLE CODES Table 7-1. Diagnostic Trouble Codes (DTC) Flash Help Message Alarm Action Trigger Code 999 FUNCTIONS LOCKED OUT - None • Drive State = PREVENTED The control system will not function because the POWER MODULE SOFTWARE •...
  • Page 172 SECTION 7 - DIAGNOSTIC TROUBLE CODES NOTES: 7-26 3121788...
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  • Page 174: General Electrical Information & Schematics

    IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELECTRICAL/ELEC- Polarity TRONIC COMPONENTS. SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- Finding a negative voltage or current reading when TRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A expecting a positive reading frequently means the leads MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPO-...
  • Page 175 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement • If meter is not auto ranging, set it to the correct • First test meter and leads by touching leads range (See multimeter’s operation manual). together. Resistance should read a short circuit (very low resistance).
  • Page 176 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement • Some meters require a separate button press to • Set up the meter for the expected current range. enable audible continuity testing. • Be sure to connect the meter leads to the correct •...

  • Page 177: Applying Silicone Dielectric Compound To Amp Connectors

    The following connector systems are specifically addressed because of their widespread use at JLG. How- ever, this guidance may be applied to similar devices. 3121788...
  • Page 178 This connector system is widely used inside enclosures This connector system is typically used on control mod- for general-purpose interconnect. Follow the general ules at JLG. Follow the general guidance for installation. guidance for installation. Mini Fit Sr AMP Faston...

  • Page 179: Amp Connector

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 8.5 AMP CONNECTOR 1. To insert a contact, push it straight into the appro- priate circuit cavity as far as it will go (See Figure 8- Assembly 3.). 2. Pull back on the contact wire with a force of 1 or 2 Check to be sure the wedge lock is in the open, or as- lbs.
  • Page 180 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 8-3. Connector Assembly Figure 2 3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is wedge lock must be closed to its locked position. flush with the housing (See Figure 8-5.).
  • Page 181 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 8-6. Connector Disassembly Disassembly Service - Voltage Reading 1. Insert a 4.8 mm (3/16 in.) wide screwdriver blade CAUTION between the mating seal and one of the red DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. wedge lock tabs.
  • Page 182 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 8-7. Connector Installation 3121788...

  • Page 183: Deutsch Connectors

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 8.6 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 8-9. DT/DTP Contact Removal Figure 8-8. DT/DTP Contact Installation 5. Remove wedgelock using needle nose pliers or a 1. Grasp crimped contact about 25mm behind the hook shaped wire to pull wedge straight out.
  • Page 184 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 8-10. HD/HDP Contact Installation Figure 8-12. HD/HDP Contact Removal 1. Grasp contact about 25mm behind the contact 4. With rear insert toward you, snap appropriate size crimp barrel.

  • Page 185: Switches

    This voltage can be seen if the measurement is taken with one test lead on the load Another type of limit switch used by JLG is the induc- and the other on the battery negative side or tive proximity switch, also referred to as a "prox...

  • Page 186: Electrical Schematics

    SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ELECTRICAL SCHEMATICS 2632R/3246R ELECTRICAL SCHEMATICS SHEET 2 : HARNESS, CHASSIS HARNESS, LIFT DOWN KIT, BATTERY CABLE CABLE, PUMP POS CABLE, PUMP NEG SHEET 3 : CABLE, PLATFORM /AC CABLE, PLATFORM CONTROL CABLE, PLATFORM CONTROL (COILED)
  • Page 187 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PMP CTRL B- TELEMATICS HARNESS, CHASSIS BEACON CHARGER INTERLOCK CONNECTS IN ZONE B8 MAIN CONTROLLER CO01-V3 WHT 18 CHARGING STAT WHT 62 BEACON SN56 BLK 1-46 BEACON GND WHT 72 GND ANGLE 1 WHT 72 GND ANGLE 1 WHT 70 5V ANGLE 1 WHT 70 5V ANGLE 1...
  • Page 188 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS CANbus Buss Bar X154 YEL CAN1-6 HIGH DIAGNOSTICS GRN CAN1-6 LOW YEL CAN1-3 HIGH GRN CAN1-3 LOW WHT 14 GND ALARM YEL 3-14 GND ALARM IGN MDI (Option) BLK 1-14 GND ALARM GND YEL 3-27 MDI IGN AH03 YEL 3-27 MDI IGN...
  • Page 189 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS CABLE, PLATFORM CONTROL 120 Ohm GRN CAN LOW GRN CAN LOW YEL CAN HIGH YEL CAN HIGH BLK GND BLK GND ORG IGNITION ORG IGNITION BLU E-STOP BLU E-STOP RED BATT POWER RED BATT POWER CABLE, PLATFORM CONTROL (COILED) CABLE, PLATFORM / AC...
  • Page 190 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS HARNESS, PLATFORM BOX JOYSTICK PLATFORM MODULE WHT 98 OVER HEAD PROTEC WHT 43-2 TRIGGER WHT 43-1 TRIGGER BLK 1-41 PLT GND SW299-1 YEL 1-5 CAN HIGH WHT 85 HORN SIG GRN 1-5 CAN LOW SW299-2 YEL 3-41 PLT PWR YEL PWR...
  • Page 191 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS DC CONNECTIONS - GREEN / EAGLE HARNESS, REMOTE TOW WHT B+ CHARGER X287 CONTACTOR B+ X281 CHARGER PLUG HV574 PUMP CONTROL B- X283 BLK B- CHARGER BLK 101-3 VLV GND WHT 102-3 TOW VLV DC CONNECTIONS - DELTA-Q X284 B- CHARGER...
  • Page 192 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PUMP CONTROL B- B+ BATT INV- BLK 57 GND BLK 6AWG WHT 56 INV ON INVERTER RED 6AWG RL165 RED 6AWG INV+ RED 6AWG SW166 WHT 56 INV ON YEL 3-4 INV IGN CONNECTS TO X275 SHEET 2 C5 INVERTER OPTION - ANSI ONLY AC CABLE...
  • Page 193 SECTION 8 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 8-20 3121788...
  • Page 194 3121788...
  • Page 195 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

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