Oshkosh JLG 2032ES Manuals

Manuals and User Guides for Oshkosh JLG 2032ES. We have 1 Oshkosh JLG 2032ES manual available for free PDF download: Service Maintenance Manual

Oshkosh JLG 2032ES Service Maintenance Manual

Oshkosh JLG 2032ES Service Maintenance Manual (180 pages)

Brand: Oshkosh | Category: Lifting Systems | Size: 22 MB

Table of Contents

Table of Contents

5
List of Tables Table No. Title Page No.

11
- MACHINE Specifications
  13
- Section 1. Specifications
  13
- Capacities
  14
- Fluid Capacities
  14
- Batteries
  15
- Battery Charger/Ac Inverter
  15
- Motors
  15
- Tires
  15
- Lift Speed
  16
- Lift Speed (no Load in Platform)
  16
- Model Dimensions
  17
- Travel Speed
  17
- Hydraulic Oil
  18
- Lubrication
  18
- Torque Requirements
  18
- Pressure Settings
  19
- High Drive Speed Cutout
  20
- Limit Switches
  20
- Tilt Alarm
  20
- Tilt Settings
  20
- Critical Stability Weights
  21
- Cylinder Specifications
  21
- Major Component Weights
  21
- Torque Charts
  22
- Annual Machine Inspection
  27
- General
  27
- Machine Preparation, Inspection, and Maintenance
  27
- Pre-Delivery Inspection and Frequent Inspection
  27
- Pre-Start Inspection
  27
- Preparation, Inspection, and Maintenance
  27
- Preventative Maintenance
  27
- Section 2 - General
  27
- Cleanliness
  28
- Components Removal and Installation
  28
- General
  28
- Inspection and Maintenance
  28
- Safety and Workmanship
  28
- Service and Guidelines
  28
- Battery
  29
- Bearings
  29
- Bolt Usage and Torque Application
  29
- Component Disassembly and Reassembly
  29
- Gaskets
  29
- Hydraulic Lines and Electrical Wiring
  29
- Hydraulic System
  29
- Lubrication
  29
- Lubrication and Servicing
  29
- Pressure-Fit Parts
  29
- Changing Hydraulic Oil
  30
- Hydraulic Oil
  30
- Hydraulic System
  30
- Lubrication and Information
  30
- Lubrication Specifications
  30
- Cylinder Drift
  31
- Cylinder Drift Test
  31
- Pins and Composite Bearing Repair Guidelines
  31
- Platform Drift
  31
- Preventive Maintenance and Inspection Schedule
  32
- Footnotes
  33
- Preventive Maintenance and Safety Inspection
  33
- Section 3 - Chassis & Scissor Arms
  35
- Theory of Operation
  35
- Traction System
  35
- Common Traction System Difficulties
  36
- Drive Motor Electrical Evaluation
  36
- Power Module Electrical Evaluation
  37
- Leak Test
  38
- Oil Check/Fill Procedure
  38
- Roll Test
  38
- Torque Hub
  38
- Brakes - Manual Disengage Procedure
  39
- Drive Motor Removal
  40
- Main Gearbox Disassembly
  41
- Input Carrier Disassembly
  42
- Hub Disassembly
  43
- Spindle Disassembly
  44
- Spindle Sub-Assembly
  45
- Hub Sub-Assembly
  46
- Input Carrier Sub-Assembly
  47
- Main Gearbox Assembly
  48
- Motor and Brake Assembly
  50
- Assembly Tools
  51
- Tightening and Torquing Bolts
  51
- 1930ES Only
  52
- Drive Motor Cable Routing
  52
- 2032ES/2632ES/2646ES/3246ES Only
  53
- Electric Drive Motor Service
  54
- Drive Motor Disassembly
  55
- Drive Motor Inspection and Service
  55
- Drive Motor Troubleshooting
  55
- Servicing Guidelines
  55
- Drive Motor Reassembly
  56
- Power Module - ZAPI
  58
- ZAPI Power Module Specs
  58
- ZAPI Power Module Electrical Evaluation
  59
- MDI (Multifunction Digital Indicator) and Brake Release
  60
- Battery Removal
  62
- Battery Charger
  63
- Battery Maintenance and Safety Practices
  63
- Battery Charger Maintenance
  64
- Battery Charger Troubleshooting
  64
- Battery Charger/Inverter (Option)
  67
- Battery Charger/Inverter Troubleshooting
  67
- Limit Switch Locations
  69
- Pothole Switch Replacement
  70
- Rotary Angle Sensor Replacement
  70
- Box Disassembly
  71
- Ground Control Station
  71
- Tilt Sensor Replacement
  72
- Platform Removal
  73
- Scissor Arms and Platform Positioning and Support
  73
- Scissor Arms Removal
  73
- Platform Control Station
  76
- Printed Circuit Board Replacement
  76
- Joystick Controller
  77
- Crossover Relief Valves
  79
- Cylinders - Theory of Operation
  79
- Manual Descent Valve
  79
- Proportional Valve
  79
- Relief Valves
  79
- Section 4 - Hydraulics
  79
- Solenoid Control Valves (Bang-Bang)
  79
- Valves - Theory of Operation
  79
- Pump Motor Electrical Evaluation
  80
- Pump/Motor - Theory of Operation
  80
- Cylinder Checking Procedure
  82
- Cylinders Without Counterbalance Valves and Steer Cylinder
  82
- Lift Pressure Setting Procedure
  82
- Hydraulic Oil Fill
  83
- Oil Check Procedure
  83
- Lift Cylinder Removal
  84
- Slide Block Lubrication
  84
- Cylinder Repair
  86
- Disassembly
  86
- Cleaning and Inspection
  87
- Steer Cylinder Piston Removal
  87
- Assembly
  88
- Cylinder Piston Nut Torque Specifications
  89
- Pump Removal
  91
- Motor Removal
  93
- Valve Torque Values
  94
- Diagnostic Port
  99
- Hand Held Analyzer
  99
- Section 5 - Jlg Control System
  99
- To Connect the Hand Held Analyzer
  99
- Using the Analyzer
  100
- Changing the Access Level of the Hand Held Analyzer
  101
- Adjusting Parameters Using the Hand Held Analyzer
  102
- Machine Model Adjustment
  102
- Machine Setup
  102
- Failure Troubleshooting for the Field
  103
- Tilt Sensor Calibration
  103
- Elevation Angle Sensor Electrical Evaluation
  104
- Tilt Sensor Electrical Evaluation
  104
- Tilt Vs. Allowed Height Evaluation
  105
- Elevation Sensor Calibration
  106
- Updating Software
  106
- Troubleshooting
  107
- Machine Model Adjustment
  125
- Machine Configuration Programming Information
  126
Section 6 - Diagnostic Trouble Codes Section 6. Diagnostic Trouble Codes

127
- DTC Index
  127
- Introduction
  127
- Section 6 - Diagnostic Trouble Codes
  127
- Alarm Sounding - Tilted & above Elevation
  130
- Driving at Cutback - above Elevation
  130
- DTC Check Tables
  130
- Everything Ok
  130
- Ground Mode Ok
  130
- Help Comments
  130
- Drive & Lift up Prevented - Tilted & Elevated
  131
- Driving at Cutback - Pothole Still Engaged
  131
- Functions Locked out - System Powered down
  131
- Lift up Prevented - Max Height Zone a
  131
- Drive Prevented - Elevated above Drive Cutout Height
  132
- Function Problem - Drive & Lift Active Together
  132
- Function Problem - Horn Permanently Selected
  132
- Function Problem - Indoor / Outdoor Permanently Selected
  132
- Keyswitch Faulty
  132
- Platform Controls
  132
- Power Cycle
  132
- Power-Up
  132
- Accelerator Faulty - Wiper out of Range
  133
- Function Locked out - Accelerator Not Centered
  133
- Function Problem - Steer Left Permanently Selected
  133
- Function Problem - Steer Right Permanently Selected
  133
- Function Problem - Trigger Permanently Closed
  133
- Steer Switches Faulty
  133
- 2210 Trigger Closed too Long While in Neutral
  134
- Function Problem - Brake Release Permanently Selected
  134
- Function Problem - Lift Permanently Selected
  134
- Ground Controls
  134
- Ground Lift up / down Active Together
  134
- Drive & Lift up Prevented - Charger Connected
  135
- Drive Prevented - Charger Connected
  135
- Elev Angle Sensor Faulty - Voltage out of Range
  135
- Elev Angle Sensor Has Not Been Calibrated
  135
- Function Prevented
  135
- Platform Overloaded
  135
- 2510 Drive Prevented - Brakes Not Releasing
  136
- 2511 Elev Angle Sensor Faulty - Not Mounted
  136
- 2512 Elev Angle Sensor Not Detecting Change
  136
- Drive & Lift Prevented - Brakes Electrically Released for Towing
  136
- Drive Prevented - Pothole Not Engaged
  136
- Elev Prox Permanently Closed - Check Prox and Angle Adjustment
  136
- Model Changed - Hydraulics Suspended - Cycle Ems
  136
- Auxiliary Relay Short to Battery
  137
- Contactor Driver Permanently off
  137
- Contactor Driver Permanently on
  137
- Line Contactor Miswired on or Welded
  137
- Line Contactor Open Circuit
  137
- Line Contactor Short Circuit
  137
- Open Circuit Line Contactor
  137
- Brake Open Circuit
  138
- Brake Short to Battery
  138
- Ground Output Driver
  138
- Lift Dn Open Circuit
  138
- Lift Dn Short to Battery
  138
- Lift up Open Circuit
  138
- Lift up Short to Battery
  138
- Steer Left Open Circuit
  138
- Steer Left Short to Battery
  138
- 3310 Steer Right Open Circuit
  139
- 3311 Ground Alarm Short to Battery
  139
- 3312 Left Brake Short to Battery
  139
- 3313 Right Brake Short to Battery
  139
- 3314 Left Brake Open Circuit
  139
- 3315 Right Brake Open Circuit
  139
- Steer Right Short to Battery
  139
- Battery Supply
  141
- Battery Voltage too Low - System Shutdown
  141
- Lss Battery Voltage too High
  141
- Lss Battery Voltage too Low
  141
- Power Module too Hot - Please Wait
  141
- Thermal Limit (SOA)
  141
- Canbus Failure - Power Module
  142
- Communication
  142
- Accessory
  144
- Accessory Fault
  144
- Canbus Failure - Accessory Module
  144
- Canbus Failure - Load Sensing System Module
  144
- Canbus Failure - Platform Module
  144
- Electric Motor
  144
- Data from Tilt Sensor - Not Connected or Faulty
  146
- Lss Cell #1 Error
  146
- Lss Cell #2 Error
  146
- Lss Cell #3 Error
  146
- Platform Load Sense
  146
- Tilt Sensor
  146
- Tilt Sensor Not Calibrated
  146
- Hardware
  147
- Lss Cell #4 Error
  147
- Lss Eeprom Error
  147
- Lss Has Not Been Calibrated
  147
- Lss Internal Error - Pin Excitation
  147
- Lss Watchdog Reset
  147
- Power Module Failure - Internal Error
  147
- Backprobing
  151
- General
  151
- Grounding
  151
- Min/Max
  151
- Multimeter Basics
  151
- Polarity
  151
- Scale
  151
- Section 7 - General Electrical Information & Schematics
  151
- Continuity Measurement over Long Distances
  154
- Procedure
  154
- Requirements
  154
- Applying Silicone Dielectric Compound to Amp Connectors
  155
- Assembly
  156
- Disassembly
  157
- Wedge Lock
  158
- Service - Voltage Reading
  159
- DT/DTP Series Assembly
  160
- DT/DTP Series Disassembly
  160
- HD30/HDP20 Series Assembly
  160
- Working with Deutsch Connectors
  160
- HD30/HDP20 Series Disassembly
  161
- Basic Check
  162
- Limit Switches
  162
- Switches
  162
- Automatic Switches
  163
- Switch Wiring - Low Side, High Side
  163
- Electrical Schematics and Layouts
  164
- Hydraulic Schematic
  174

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